Absorbent article with waistband

ABSTRACT

A disposable absorbent article is disclosed that includes a first waist region, a second waist region, a crotch region disposed between the first waist region and second waist region, a waist edge in the first waist region, at least one waistband in the first waist region, at least one fastener in the second waist region, and at least one discrete landing zone in the first waist region, the discrete landing zone comprising an lateral inboard edge, wherein the discrete landing zone and the waistband overlap to form an overlap region in the first waist region, and wherein the waistband does not overlap the lateral inboard edge of the discrete landing zone.

FIELD OF INVENTION

This disclosure relates to open form disposable absorbent articles, suchas diapers, having improved waistband properties that yield a moreunderwear-like article. The absorbent article may have improvedfunctional characteristics and communicative properties.

BACKGROUND OF THE INVENTION

Disposable absorbent articles which have a conforming, underwear-likefit are more desirable for moms and babies because it allows them toaspire to a time when the baby will be potty trained and no longer indiapers. Thus, an absorbent product that can deliver an underwear-likeperception is more desirable than one that does not. A common featureamong underwear is a continuous stretchable waistband along the top ofthe product, which allows the top of the underwear to resist rolling,flipping and/or scrunching during wear. Said another way, the continuousstretchable waistband promotes continuous contact between the top of theunderwear and the wearer's body. This promotion of continuous contactmay be achieved because the waistband is configured to have continuoustension at the top edge of the underwear. Accordingly, the continuousstretchable waistband makes it energetically unfavorable for anyparticular portion of the waistband to move away from the surface of thebody (e.g., roll, flip and/or scrunch). In addition, if any portion ofcontinuous stretchable waistband does move away from the surface of thebody, the continuous stretchable waistband also makes it energeticallyfavorable for the waistband to return to its original position incontact with the wearer's body.

Many disposable absorbent articles are configured in an open form (e.g.,taped diapers) so they can be fastened around a wearer's torso andadjusted accordingly. This structure may allow for easy application andremoval of the absorbent articles, may be less expensive to manufactureversus pant type absorbent articles, and allows the products to fit awider range of wearers with different body shapes and sizes. Despitebeing an open form product, it is still desirable for the product to beperceived like underwear for the reasons stated above. Open formabsorbent articles, however, do not have a continuous stretchablewaistband which encircles the waist of the wearer. Thus, whenstretchable materials are employed on an open form disposable absorbentarticle in a waist region (e.g., a front waist feature such as a frontwaistband), such materials often do not maintain continuous contact withthe wearer's body and roll, flip and/or scrunch during wear. As anexample, this phenomenon can often be seen when a taped diaper beingworn by a baby has the top front region above the tape fasteners flippedover and not in contact with the baby's stomach.

Prior solutions to rolling, flipping and/or scrunching of the frontwaist region of an open form disposable absorbent article have includedadditional fastening elements to secure the loose ends of the front ofthe product. Fastening elements, however, increase cost and riskirritating the wearer's skin. Further, when used with stretch elementsor a non-stretchable waist region, additional fastening elements cancreate a fit which limits the stretch and is tight and uncomfortable fora wearer. Other proposed solutions have included regions of highstiffness to provide additional support to the waist region of theproduct. The high stiffness in the waist region resists the bending orbuckling force exerted by the wearer. However, the high stiffness alsoresults in a front waist region which does not conform to the body ofthe wearer as the body continuously changes shape during use due to awearer's posture, breathing, food intake, etc., and therefore isuncomfortable for the wearer.

It is thus desirable to have a front waist region with a stretchablefront waist feature (e.g., a front waistband) in an open form disposableabsorbent article which is inexpensive to manufacture, wherein the frontwaist region is flexible and comfortable to wear, promotes continuouscontact with the wearer's body, resists rolling, flipping or scrunching,and if the front waist region does roll, flip or scrunch, has a tendencyto return to its original position in contact with the wearer's body.

SUMMARY OF THE INVENTION

In one embodiment, the open form disposable absorbent articles detailedherein include a first waist region, a second waist region, a crotchregion disposed between the first waist region and second waist region,a waist edge in the first waist region, at least one waistband in thefirst waist region adjacent the waist edge, and at least one fastener inthe second waist region, wherein the first waist region has a resiliencyof greater than about 5 mJ and a stiffness of less than about 10 N.

In another embodiment, the open form disposable absorbent articlesdetailed herein include a first waist region, a second waist region, acrotch region disposed between the first waist region and second waistregion, a waist edge in the first waist region, at least one waistbandin the first waist region adjacent the waist edge, and at least one earin the second waist region, wherein the first waist region has a firstsection, a second section, a third section, a fourth section, a fifthsection, a sixth section, a seventh section, an eighth section and aninth section, wherein the stiffness of the second section is less thanabout 10 N, and wherein the difference in resiliency between twoadjacent sections is not more than about 60% of the average resiliencyof all of the sections.

In another embodiment, the open form disposable absorbent articlesdetailed herein include a first waist region, a second waist region, acrotch region disposed between the first waist region and second waistregion, a waist edge in the first waist region, at least one waistbandin the first waist region adjacent the waist edge, at least one fastenerin the second waist region, and a waist assembly in the first waistregion, wherein the waist assembly has a Corrugation Regularity greaterthan about 75%.

In another embodiment, the open form disposable absorbent articlesdetailed herein include a first waist region, a second waist region, acrotch region disposed between the first waist region and second waistregion, a waist edge in the first waist region, at least one waistbandin the first waist region adjacent the waist edge, at least one fastenerin the second waist region, and a waist assembly in the first waistregion; wherein the waist assembly has a Corrugation Uniformity ofgreater than about 50%.

In another embodiment, the open form disposable absorbent articlesdetailed herein include a first waist region, a second waist region, acrotch region disposed between the first waist region and second waistregion, a waist edge in the first waist region, at least one waistbandin the first waist region, at least one fastener in the second waistregion, and at least one discrete landing zone in the first waistregion, the discrete landing zone comprising an lateral inboard edge,wherein the discrete landing zone and the waistband overlap to form anoverlap region in the first waist region, and wherein the waistband doesnot overlap the lateral inboard edge of the discrete landing zone.

In another embodiment, the open form disposable absorbent articlesdetailed herein include a first waist region, a second waist region, acrotch region disposed between the first waist region and second waistregion, a waist edge in the first waist region, at least one waistbandin the first waist region, at least one fastener in the second waistregion, a topsheet, a backsheet, and an absorbent core disposed betweenthe topsheet and backsheet, the absorbent core having a lateral edgedisposed in the first waist region, said lateral edge of the core beinginboard of the waist edge in the first waist region; wherein theabsorbent core and the waistband overlap to form an overlap region inthe first waist region.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of an embodiment of the open form disposableabsorbent articles detailed herein.

FIG. 2 is a plan view of an embodiment of a waistband laminate suitablefor use in the absorbent articles detailed herein.

FIG. 3 is a plan view of an embodiment of the absorbent article detailedherein.

FIG. 4 is a schematic cross section view of an embodiment of a foldedouter leg cuff suitable for use in the absorbent articles detailedherein.

FIG. 5 is a schematic cross section view of an embodiment of a foldedouter leg cuff suitable for use in the absorbent articles detailedherein.

FIG. 6 is a schematic cross section view of an embodiment of anabsorbent core suitable for use in the absorbent articles detailedherein.

FIG. 7 is a schematic cross section view of an embodiment of anabsorbent core suitable for use in the absorbent articles detailedherein.

FIG. 8 is a schematic cross section view of an embodiment of anabsorbent core suitable for use in the absorbent articles detailedherein.

FIGS. 9a-d are schematic cross section views of embodiments of waistbandlaminates suitable for use in the absorbent articles detailed herein.

FIG. 10 is a schematic representation of a template.

FIG. 11 is an enlarged view of the front waist region of the exemplaryopen form disposable absorbent article of FIG. 1.

FIG. 12 A-D illustrate an embodiment of a non-woven with a deepcontinuous bond pattern that can be elastically gathered to includeregular and consistent corrugations.

FIG. 13 A-D illustrate an embodiment of a non-woven with a deepcontinuous bond pattern that can be elastically gathered to includeregular and consistent corrugations.

FIG. 14 is a photograph of an embodiment of a waistband suitable for usein the open form disposable absorbent articles detailed herein.

FIG. 15 is a photograph of a waistband without regular and uniformcorrugations.

FIG. 16 is a photograph of a waistband without regular and uniformcorrugations.

FIG. 17 is a schematic representation of a top view of the garmentfacing surface of an exemplary open form disposable absorbent article.

FIG. 18 is a schematic representation of a top view of the body facingsurface of an exemplary open form disposable absorbent article.

FIG. 19 is a schematic representation of a top view of the body facingsurface of an exemplary open form disposable absorbent article.

FIG. 20 is a schematic representation of a side view of a portion of theapparatus used to measure resiliency and stiffness as detailed herein.

FIG. 21 is a schematic representation of a front view of a portion ofthe apparatus used to measure resiliency and stiffness as detailedherein.

FIG. 22 is a schematic representation of exemplary specimen secured tothe testing surface of the apparatus illustrated in FIGS. 20 and 21.

FIG. 23 is an exemplary graph charting the data generated by the TestWorks 4 software when being used for resiliency and stiffnessmeasurements.

DETAILED DESCRIPTION OF THE INVENTION

As used herein, the following terms shall have the meaning specifiedthereafter:

“Disposable,” in reference to absorbent articles, means that theabsorbent articles are generally not intended to be laundered orotherwise restored or reused as absorbent articles (i.e., they areintended to be discarded after a single use and, preferably, to berecycled, composted or otherwise discarded in an environmentallycompatible manner).

“Absorbent article” refers to devices which absorb and contain bodyexudates and, more specifically, refers to devices which are placedagainst or in proximity to the body of the wearer to absorb and containthe various exudates discharged from the body. Exemplary absorbentarticles include diapers, training pants, pull-on pant-type diapers(i.e., a diaper having a pre-formed waist opening and leg openings suchas illustrated in U.S. Pat. No. 6,120,487), refastenable diapers orpant-type diapers, incontinence briefs and undergarments, diaper holdersand liners, feminine hygiene garments such as panty liners, absorbentinserts, and the like.

“Proximal” and “Distal” refer respectively to the location of an elementrelatively near to or far from the longitudinal or lateral centerline ofa structure (e.g., the proximal edge of a longitudinally extendingelement is located nearer to the longitudinal centerline than the distaledge of the same element is located relative to the same longitudinalcenterline).

“Inboard” and “Outboard” refer respectively to the location of anelement relative a centerline (longitudinal or lateral) of the absorbentarticle. Inboard refers to a location closer to the centerline andoutboard refers to a location further from the centerline.

“Body-facing” and “garment-facing” refer respectively to the relativelocation of an element or a surface of an element or group of elements.“Body-facing” implies the element or surface is nearer to the wearerduring wear than some other element or surface. “Garment-facing” impliesthe element or surface is more remote from the wearer during wear thansome other element or surface (i.e., element or surface is proximate tothe wearer's garments that may be worn over the disposable absorbentarticle).

“Longitudinal” refers to a direction running substantially perpendicularfrom a waist edge to an opposing waist edge of the article and generallyparallel to the maximum linear dimension of the article. Directionswithin 45 degrees of the longitudinal direction are considered to be“longitudinal”

“Lateral” refers to a direction running from a longitudinal edge to anopposing longitudinal edge of the article and generally at a right angleto the longitudinal direction. Directions within 45 degrees of thelateral direction are considered to be “lateral.”

“Disposed” refers to an element being located in a particular place orposition.

“Joined” refers to configurations whereby an element is directly securedto another element by affixing the element directly to the other elementand to configurations whereby an element is indirectly secured toanother element by affixing the element to intermediate member(s) whichin turn are affixed to the other element.

“Film” refers to a sheet-like material wherein the length and width ofthe material far exceed the thickness of the material. Typically, filmshave a thickness of about 0.5 mm or less.

“Water-permeable” and “water-impermeable” refer to the penetrability ofmaterials in the context of the intended usage of disposable absorbentarticles. Specifically, the term “water-permeable” refers to a layer ora layered structure having pores, openings, and/or interconnected voidspaces that permit liquid water, urine, or synthetic urine to passthrough its thickness in the absence of a forcing pressure. Conversely,the term “water-impermeable” refers to a layer or a layered structurethrough the thickness of which liquid water, urine, or synthetic urinecannot pass in the absence of a forcing pressure (aside from naturalforces such as gravity). A layer or a layered structure that iswater-impermeable according to this definition may be permeable to watervapor, i.e., may be “vapor-permeable.”

“Extendibility” and “extensible” mean that the width or length of thecomponent in a relaxed state can be extended or increased.

“Elasticated” and “elasticized” mean that a component comprises at leasta portion made of elastic material.

“Elongatable material,” “extensible material,” or “stretchable material”are used interchangeably and refer to a material that, upon applicationof a biasing force, can stretch to an elongated length of at least about110% of its relaxed, original length (i.e. can stretch to 10 percentmore than its original length), without rupture or breakage, and uponrelease of the applied force, shows little recovery, less than about 20%of its elongation without complete rupture or breakage as measured byEDANA method 20.2-89. In the event such an elongatable material recoversat least 40% of its elongation upon release of the applied force, theelongatable material will be considered to be “elastic” or“elastomeric.” For example, an elastic material that has an initiallength of 100 mm can extend at least to 150 mm, and upon removal of theforce retracts to a length of at least 130 mm (i.e., exhibiting a 40%recovery). In the event the material recovers less than 40% of itselongation upon release of the applied force, the elongatable materialwill be considered to be “substantially non-elastic” or “substantiallynon-elastomeric”. For example, an elongatable material that has aninitial length of 100 mm can extend at least to 150 mm, and upon removalof the force retracts to a length of at least 145 mm (i.e., exhibiting a10% recovery).

“Discrete landing zone” refers to a component of a fastening element,typically but not limited to, the female engaging portion of a hook andloop fastening system. The discrete landing zone is a discrete componentthat is attached to the garment facing surface of an open formdisposable article.

“Elastomeric material” is a material exhibiting elastic properties.Elastomeric materials may include elastomeric films, strands, scrims,nonwovens, and other sheet-like structures.

“Pant” refers to disposable absorbent articles having a pre-formed waistand leg openings. A pant may be donned by inserting a wearer's legs intothe leg openings and sliding the pant into position about the wearer'slower torso. Pants are also commonly referred to as “closed diapers”,“prefastened diapers”, “pull-on diapers”, “training pants” and“diaper-pants.”

“Open form” refers to disposable absorbent articles which do not includepre-formed waist and leg openings, and employ fasteners to secure thediaper around the waist of the wearer. FIGS. 1 and 3 are illustrativeexamples of open form disposable absorbent articles.

“Corrugations” refers to wrinkles or deformations of a material in thez-axis (i.e., out of plane of the diaper in FIG. 1). Corrugations may beused interchangeably with the term “gathers.”

“Regular corrugations” refers to corrugations which substantially occurat a single primary frequency. For example, one embodiment of regularcorrugations is a set of corrugations that have a space between thepeaks of the corrugations where no more than 25% of the spaces vary fromthe average spacing by more than plus or minus 1 mm.

A “uniform corrugation” refers to a corrugation which spans thelongitudinal length of the waist assembly of the first waist regionwithout being broken or disrupted, as further detailed in the method ofcalculating Corrugation Uniformity herein. A waist assembly isconsidered to be uniformly corrugated if at least one surface (e.g.,body facing surface or garment facing surface) has more than 50%corrugations that are uniform corrugations.

“Waistband” refers to a discretely applied component in at least firstwaist region, and can be applied on the garment facing surface, the bodyfacing surface, or sandwiched between layers of the absorbent article.

“Waist assembly” refers a general region of the absorbent article wherea waistband could be discretely applied. This region generally includesmultiple layers of the absorbent article, including but not limited to,topsheet, backsheet (microporous film and/or outer cover), discretelanding zone, absorbent assembly (or portions thereof), leg gasketingsystem, opacity strengthening patches, etc. If the absorbent articleincludes a waistband and the waistband is less than 25 mm long in thelongitudinal direction, the waist assembly is defined as the areabetween the waist edge of the first waist region and the inboard edge ofthe waistband. If there is no waistband or the waistband of theabsorbent article is more than 25 mm long in the longitudinal direction,this region is defined as the area between the waist edge of the firstwaist region and a line parallel to, and 25 mm inboard, of the waistedge of the first waist region.

FIG. 1 is a plan view of an exemplary, non-limiting embodiment of anopen form disposable absorbent article 20 in a flat, uncontracted state(i.e., without elastic induced contraction). The garment-facing surface120 of the absorbent article 20 is facing the viewer. The absorbentarticle 20 includes a longitudinal centerline 100 and a lateralcenterline 110. The absorbent article 20 may comprise a chassis 22. Theabsorbent article 20 and chassis 22 are shown to have a first waistregion 36, a second waist region 38 opposed to the first waist region36, and a crotch region 37 located between the first waist region 36 andthe second waist region 38. The waist regions 36 and 38 generallycomprise those portions of the absorbent article 20 which, when worn,encircle the waist of the wearer. The waist regions 36 and 38 mayinclude elastic elements such that they gather about the waist of thewearer to provide improved fit and containment. The waist regions 36 and38 may include a first waistband 1000 and a second waistband 2000. Thecrotch region 37 is that portion of the absorbent article 20 which, whenthe absorbent article 20 is worn, is generally positioned between thelegs of the wearer.

The outer periphery of chassis 22 is defined by longitudinal edges 12and waist edges 14. The longitudinal edges 12 may be subdivided into afront longitudinal edge 12 a, which is the portion of the longitudinaledge 12 in the first waist region 36, and a rear longitudinal edge 12 b,which is the portion of the longitudinal edge 12 in the rear waistregion 38. The chassis 22 may have opposing longitudinal edges 12 thatare oriented generally parallel to the longitudinal centerline 100.However, for better fit, longitudinal edges 12 may be curved or angledto produce, for example, an “hourglass” shape diaper when viewed in aplan view. The chassis 22 may have opposing waist edges 14 that areoriented generally parallel to the lateral centerline 110.

The chassis 22 may comprise a liquid permeable topsheet 24, a backsheet26, and an absorbent core 28 between the topsheet 24 and the backsheet26. The absorbent core 28 may have a body-facing surface and a garmentfacing-surface. The topsheet 24 may be joined to the core 28 and/or thebacksheet 26. The backsheet 26 may be joined to the core 28 and/or thetopsheet 24. It should be recognized that other structures, elements, orsubstrates may be positioned between the core 28 and the topsheet 24and/or backsheet 26. In certain embodiments, the chassis 22 comprisesthe main structure of the absorbent article 20 with other features addedto form the composite diaper structure. While the topsheet 24, thebacksheet 26, and the absorbent core 28 may be assembled in a variety ofwell-known configurations, preferred diaper configurations are describedgenerally in U.S. Pat. Nos. 3,860,003; 5,151,092; 5,221,274; 5,554,145;5,569,234; 5,580,411; and 6,004,306.

The topsheet 24 is generally a portion of the absorbent article 20 thatmay be positioned at least in partial contact or close proximity to awearer. Suitable topsheets 24 may be manufactured from a wide range ofmaterials, such as porous foams; reticulated foams; apertured plasticfilms; or woven or nonwoven webs of natural fibers (e.g., wood or cottonfibers), synthetic fibers (e.g., polyester or polypropylene fibers), ora combination of natural and synthetic fibers. The topsheet 24 isgenerally supple, soft feeling, and non-irritating to a wearer's skin.Generally, at least a portion of the topsheet 24 is liquid pervious,permitting liquid to readily penetrate through the thickness of thetopsheet 24. The topsheet 24 may include apertures. One topsheet 24useful herein is available from BBA Fiberweb, Brentwood, Tenn. assupplier code 055SLPV09U.

Any portion of the topsheet 24 may be coated with a lotion or skin carecomposition as is known in the art. Examples of suitable lotions includethose described in U.S. Pat. Nos. 5,607,760; 5,609,587; 5,635,191; and5,643,588. The topsheet 24 may be fully or partially elasticized or maybe foreshortened so as to provide a void space between the topsheet 24and the core 28. Exemplary structures including elasticized orforeshortened topsheets are described in more detail in U.S. Pat. Nos.4,892,536; 4,990,147; 5,037,416; and 5,269,775.

The absorbent core 28 may comprise a core cover, a dusting layer, and awide variety of liquid-absorbent materials commonly used in disposablediapers and other absorbent articles. The core cover and the dustinglayer may be made from non-woven materials, or from any other materialknown in the art that can be employed as a core cover or a dustinglayer. Some embodiments of the absorbent core do not include a corecover or a dusting layer.

Examples of suitable absorbent materials include comminuted wood pulp,which is generally referred to as air felt creped cellulose wadding;melt blown polymers, including co-form; chemically stiffened, modifiedor cross-linked cellulosic fibers; tissue, including tissue wraps andtissue laminates; absorbent foams; absorbent sponges; superabsorbentpolymers; absorbent gelling materials; or any other known absorbentmaterial or combinations of materials. In one embodiment, at least aportion of the absorbent core is substantially cellulose free andcontains less than 10% by weight cellulosic fibers, less than 5%cellulosic fibers, less than 1% cellulosic fibers, no more than animmaterial amount of cellulosic fibers or no cellulosic fibers. Itshould be understood that an immaterial amount of cellulosic materialdoes not materially affect at least one of the thinness, flexibility,and absorbency of the portion of the absorbent core that issubstantially cellulose free. Among other benefits, it is believed thatwhen at least a portion of the absorbent core is substantially cellulosefree, this portion of the absorbent core is significantly thinner andmore flexible than a similar absorbent core that includes more than 10%by weight of cellulosic fibers. The amount of absorbent material, suchas absorbent particulate polymer material present in the absorbent coremay vary, but in certain embodiments, is present in the absorbent corein an amount greater than about 80% by weight of the absorbent core, orgreater than about 85% by weight of the absorbent core, or greater thanabout 90% by weight of the absorbent core, or greater than about 95% byweight of the core. Non-limiting examples of suitable absorbent coresare described in greater details below.

Exemplary absorbent structures for use as the absorbent core 28 aredescribed in U.S. Pat. Nos. 4,610,678; 4,673,402; 4,834,735; 4,888,231;5,137,537; 5,147,345; 5,342,338; 5,260,345; 5,387,207; 5,397,316; and5,625,222.

The backsheet 26 is generally positioned such that it may be at least aportion of the garment-facing surface 120 of the absorbent article 20.Backsheet 26 may be designed to prevent the exudates absorbed by andcontained within the absorbent article 20 from soiling articles that maycontact the absorbent article 20, such as bed sheets and undergarments.In certain embodiments, the backsheet 26 is substantiallywater-impermeable. Suitable backsheet 26 materials include films such asthose manufactured by Tredegar Industries Inc. of Terre Haute, Ind. andsold under the trade names X15306, X10962, and X10964. Other suitablebacksheet 26 materials may include breathable materials that permitvapors to escape from the absorbent article 20 while still preventingexudates from passing through the backsheet 26. Exemplary breathablematerials may include materials such as woven webs, nonwoven webs,composite materials such as film-coated nonwoven webs, and microporousfilms such as manufactured by Mitsui Toatsu Co., of Japan under thedesignation ESPOIR NO and by EXXON Chemical Co., of Bay City, Tex.,under the designation EXXAIRE. Suitable breathable composite materialscomprising polymer blends are available from Clopay Corporation,Cincinnati, Ohio under the name HYTREL blend P18-3097. Such breathablecomposite materials are described in greater detail in PCT ApplicationNo. WO 95/16746 and U.S. Pat. No. 5,865,823. Other breathable backsheetsincluding nonwoven webs and apertured formed films are described in U.S.Pat. No. 5,571,096. An exemplary, suitable backsheet is disclosed inU.S. Pat. No. 6,107,537. Other suitable materials and/or manufacturingtechniques may be used to provide a suitable backsheet 26 including, butnot limited to, surface treatments, particular film selections andprocessing, particular filament selections and processing, etc.

Backsheet 26 may also consist of more than one layer. The backsheet 26may comprise an outer cover and an inner layer. The outer cover may bemade of a soft, non-woven material. The inner layer may be made of asubstantially liquid-impermeable film. The outer cover and an innerlayer may be joined together by adhesive or any other suitable materialor method. A particularly suitable outer cover is available from CorovinGmbH, Peine, Germany as supplier code A18AH0, and a particularlysuitable inner layer is available from RKW Gronau GmbH, Gronau, Germanyas supplier code PGBR4WPR. While a variety of backsheet configurationsare contemplated herein, it would be obvious to those skilled in the artthat various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention.

The absorbent article 20 may include front ears 40 and/or back ears 42.The ears 40, 42 may be extensible, inextensible, elastic, or inelastic.The ears 40, 42 may be formed from nonwoven webs, woven webs, knittedfabrics, polymeric and elastomeric films, apertured films, sponges,foams, scrims, and combinations and laminates thereof. In certainembodiments the ears 40, 42 may be formed of a stretch laminate such asa nonwoven/elastomeric material laminate or a nonwoven/elastomericmaterial/nonwoven laminate. Stretch laminates may be formed by anymethod known in the art. For example, the ears 40, 42 may be formed as azero strain stretch laminate, which includes at least a layer ofnon-woven material and an elastomeric element. The elastomeric elementis attached to the layer of non-woven material while in a relaxed orsubstantially relaxed state, and the resulting laminate is madestretchable (or more stretchable over a further range) by subjecting thelaminate to an activation process which elongates the nonwoven layerpermanently, but the elastomeric element temporarily. The nonwoven layermay be integral with at least a portion of the chassis 22, in which casethe elastomeric element may be attached to the nonwoven layer and thenon-woven/elastomeric element laminate is subsequently activated.Alternatively, the nonwoven layer may be a separate component, in whichcase the elastomeric element is attached to the nonwoven layer to formthe laminate, which is then coupled to the main portion. If one or morelayers of the ear are provided separately, the laminate may be activatedeither before or after attachment to the main portion. The zero strainactivation processes is further disclosed in U.S. Pat. Nos. 5,167,897and 5,156,793. A suitable elastic ear may be an activated laminatecomprising an elastomeric film (such as is available from Tredegar Corp,Richmond, Va., as supplier code X25007) disposed between two nonwovenlayers (such as is available from BBA Fiberweb, Brentwood, Tenn. assupplier code FPN332).

The ears 40, 42 may be discrete or integral. A discrete ear is formed asseparate element which is joined to the chassis 22. An integral ear is aportion of the chassis 22 that projects laterally outward from thelongitudinal edge 12. The integral ear may be formed by cutting thechassis form to include the shape of the ear projection.

The absorbent article 20 may also include a fastening system 50. Whenfastened, the fastening system 50 interconnects the first waist region36 and the second waist region 38 resulting in a waist circumferencethat may encircle the wearer during wear of the absorbent article 20.The fastening system 50 may comprises a fastener such as tape tabs, hookand loop fastening components, interlocking fasteners such as tabs &slots, buckles, buttons, snaps, and/or hermaphroditic fasteningcomponents, although any other known fastening means are generallyacceptable. Some exemplary surface fastening systems are disclosed inU.S. Pat. Nos. 3,848,594; 4,662,875; 4,846,815; 4,894,060; 4,946,527;5,151,092; and 5,221,274. An exemplary interlocking fastening system isdisclosed in U.S. Pat. No. 6,432,098. The fastening system 50 may alsoprovide a means for holding the article in a disposal configuration asdisclosed in U.S. Pat. No. 4,963,140. The fastening system 50 may alsoinclude primary and secondary fastening systems, as disclosed in U.S.Pat. No. 4,699,622. The fastening system 50 may be constructed to reduceshifting of overlapped portions or to improve fit as disclosed in U.S.Pat. Nos. 5,242,436; 5,499,978; 5,507,736; and 5,591,152.

Waistbands of the disposable absorbent articles detailed herein mayresult in absorbent articles having increased comfort, fit, and improvedleakage performance for the wearer. Certain waistbands may also provideimproved product durability and strength. The waistbands of thedisposable absorbent articles detailed herein may also result an easierand improved absorbent article changing experience.

One object of the disposable absorbent articles detailed herein is todeliver an absorbent article having improved gap closure in the firstand/or second waist regions of the absorbent article than what iscurrently known in the art today. Having gap closure in the waistregions may create an article with better fit and containment, resultingin improved leakage performance. One way to achieve gap closure is toprovide a waistband that is flush coterminous with the rear waist edgeof the absorbent article. Because there is variation in the applicationprocess, in some embodiments, a waistband may be present in both thefirst and second waist regions of the absorbent article. However, whilea highly contracted waistband is desirable for the back waist region toprovide gap closure, it may be more desirable to have a less contractedwaistband in the front waist region to aid in application. Therefore,one embodiment of the disposable absorbent articles detailed herein isdirected to “differential contraction” or waistband laminates havingdifferent installed elongation strands in the front versus the back,such that only one waistband laminate is cut. Cutting of the waistbandlaminate is subsequent to the waistband application to the article; thewaistband is applied such that it spans the intended article separation(cut) zone. Thus, the same waistband laminate can deliver differentlevels of contraction in the back and front, resulting in highercontraction in the back to help close the gap and lower contraction inthe front.

In one embodiment, the first (1000) and second waistbands (2000) arecomprised of a waistband laminate (3000). In one embodiment, thewaistband laminate is comprised of a nonwoven material (3100). In oneembodiment, the waistband laminate is comprised of a film. In oneembodiment, the waistband laminate is comprised of at least two elasticstrands (3200), at least four elastic strands, at least six elasticstrands, at least eight elastic strands, at least ten elastic strands,at least twelve elastic strands. Although the description and figuresare mainly directed towards waistband laminates that include elasticstrands, the teachings herein (e.g., material strains, elongations,ratios) are also applicable to waistband embodiments that containelastomeric films, foams, or other stretchable materials used inwaistband construction.

In one embodiment, the first and second waistbands are applied to thearticle at the same applied waistband strain. In one embodiment, thefirst waistband and the second waistband are applied to the disposableabsorbent article at a strain of greater than about 30%, greater thanabout 50%, greater than about 70% as compared to the relaxed length. Inone embodiment, the first waistband and the second waistband are appliedto the disposable absorbent article at a strain of less than about 150%,less than about 125%, less than about 100%, less than about 75% ascompared to the relaxed length. In one embodiment, the first waistbandand the second waistband are applied to the disposable absorbent articleat a strain of from about 70% to about 75% as compared to the relaxedlength.

In one embodiment, the waistband laminate is comprised of a nonwovenmaterial and at least two elastic strands, wherein each of the at leasttwo elastic strands are different elastic materials. In one embodiment,the elastic strands may be round in cross section; however, otherembodiments may have elastic strands of varying cross sectiongeometries. In one embodiment, the elastic strands have differentdiameters or cross-sectional geometries.

In one embodiment, the waistband laminate is cut after application tothe article between the elastic strands such that a waistband laminatecomprised of at least two elastic strands results in two waistbands eachhaving one elastic strand; a waistband laminate comprised of at leastfour elastic strands results in two waistbands each having two elasticstrands. As shown in FIG. 2, a waistband laminate 3000 comprised of atleast six elastic strands results in two waistbands (1000, 2000) eachhaving three elastic strands when cut (cut line 4000). Further, awaistband laminate comprised of at least eight elastic strands resultsin two waistbands each having four elastic strands, a waistband laminatecomprised of at least ten elastic strands results in two waistbands eachhaving five elastic strands, a waistband laminate comprised of at leasttwelve elastic strands results in two waistbands each having six elasticstrands. In one embodiment, the waistband laminate is cut such that thetwo resulting waistbands have an unequal distribution of elastic strandsor having no elastic strands on one side of the cut. For example, awaistband laminate having ten elastic strands may result in onewaistband having six elastics and one waistband having four elastics. Inanother example, a waistband laminate having ten elastic strands mayresult in one waistband having ten elastics and one waistband having noelastics. In one embodiment, the waistband laminate is cut in the centerto create the two waistbands. In one embodiment, the waistband laminateis cut off-center. In one embodiment, the waistband laminate may haveelastic strands spaced equally apart. In one embodiment, the waistbandlaminate may have strands spaced closer together or further apart ascompared to the other elastic strands in the laminate.

In one embodiment, the waistband has a length in the direction parallelto the longitudinal axis of the article of greater than about 12 mm,greater than about 15 mm, greater than about 20 mm. In one embodiment,the waistband has a length in the direction parallel to the longitudinalaxis of the article of less than about 50 mm, less than about 45 mm,less than about 40 mm. In one embodiment, the waistband has a length inthe direction parallel to the longitudinal axis of the article of about25 mm.

In one embodiment, the waistband in a relaxed product has a length inthe direction parallel to the lateral axis of the article of greaterthan about 50 mm, greater than about 75 mm, greater than about 100 mm.In one embodiment, the length in the direction parallel to the lateralaxis of the article of the waistband in a relaxed product is less thanabout 300 mm, less than about 250 mm, less than about 200 mm.

In one embodiment, the CD Length Ratio of the waistband compared to thedistance from one tape to the other tape is less than about 2, less thanabout 1.5, about 1.

In one embodiment, the waistband is on the body-facing surface of thearticle. In one embodiment, the waistband is on the garment-facingsurface of the article. In one embodiment, the waistband is sandwichedin between the layers of the absorbent article. In one embodiment, thewaistband is on the garment-facing surface in either the first or secondwaist regions and on the body-facing surface in either the first orsecond waist regions. In one embodiment, the waistband is on both thebody-facing surface and the garment-facing surface. In one embodiment,the waistband is on either the body-facing surface or the garment-facingsurface and the surface not comprising the waistband is printed with aprinted waistband feature.

In one embodiment, when the waistband is in a relaxed state (i.e., thewaistband is contracted), the distance from one tape edge to the othertape edge is at least about 50% the average length of the baby waistcircumference for an average baby that wears the size of absorbentarticle; at least about 60% the average length; at least about 65% theaverage length.

In one embodiment, the elastic strands of the waistband laminate mayhave different installed elongations within one laminate, thus, afterbeing cut, resulting in a first waistband having a first installedelongation and a second waistband having a second installed elongation;both the first and second waistbands have the same applied waistbandstrain. The installed elongation is the strain at which the elastic isunder relative to the second material that it is combined with (e.g. lowbasis weight nonwoven). For example, if the elastic is stretched from100 mm to 250 mm when it is combined with the nonwoven, it would be saidto be 150% installed elongation or ((250 mm/100 mm)−1)×100%. Thislaminate can then be allowed to relax and will return to about theoriginal 100 mm, but with 250 mm of nonwoven. There can be more than oneinstalled elongation within one waistband laminate if the elastics arestrained to a different degree. For example, strand (1) is stretchedfrom 100 mm to 250 mm when combined with the nonwoven or has 150%installed elongation while strand (2) is stretched from 90 mm to 250 mmwhen combined with the NW or has an installed elongation of about 178%.

The Applied Waistband Strain is the strain that the waistband laminateis under when combined with the absorbent article. For example if 100 mmof laminate is stretched to 170 mm when applied it would be consideredto be 70% applied waistband strain or ((170 mm−100 mm)/100 mm×100%). Inone embodiment, the first installed elongation of any number of elasticstrands is about 100%, about 125%, about 140%, about 150%, about 160%,about 175%, about 200%. In one embodiment the second installedelongation of any number of elastic strands is about 100%, about 125%,about 140%, about 150%, about 160%, about 175%, about 200%.

In one embodiment, the delta between the first installed elongation andthe second installed elongation is greater than about 20%, greater thanabout 30%, greater than about 40%.

In one embodiment, the resulting Front-to-Back Delta Chassis Contractionis greater than about 5.0%, greater than about 9.0%, greater than about9.5%, greater than about 12.5%, greater than about 15%, greater thanabout 20%.

In one embodiment, the Front-to-Back Delta Chassis Contraction is lessthan about 15%, less than about 12.5%, less than about 10%, less thanabout 9.5%, less than about 9% when either the front chassis contractionor the back chassis contraction is greater than about 18%, greater thanabout 20%.

Another object of the disposable absorbent articles detailed herein isto deliver a better balance of thickness (caliper)/cushion andcontraction in a waistband than what is currently known in the art.Presently, most waistbands are either foam based which have goodcushion/caliper for comfort and containment but are limited in theamount of contraction or the waistbands are a combination of elasticstrands and nonwoven where the elastic strands are pulled at high strainwhich delivers high contraction, but very little caliper/cushion in use.Thus, one embodiment of the disposable absorbent articles detailedherein is directed to “consolidation” which provides a waistband havingthe nonwoven material and the elastic strand(s) combined under a higherfirst strain (installed elongation) and the resulting waistband attachedto the article under a lower applied waistband strain, such that thefolded up nonwoven in the waistband provides a cushion/caliper in boththe relaxed and stretched/in use states. FIG. 9 depicts cross sectionalviews of the waistband laminate (3000). FIGS. 9a-b depict cross sectionsof the waistband with no extended consolidation. FIG. 9a depicts arelaxed product cross section at the waist, parallel to the lateral axisof the diaper chassis (22). FIG. 9b shows an extended product crosssection at the waist, parallel to the lateral axis of the diaper. FIGS.9c-d depict cross sections of the waistband with extended consolidation.FIG. 9c shows a relaxed product cross section at the waist, parallel tothe lateral axis of the diaper. FIG. 9c shows that the frequency andamplitude of the waistband is higher than that of the chassis it isapplied to. FIG. 9d shows an extended product cross section at thewaist, parallel to the lateral axis of the diaper. FIG. 9d shows thateven when the chassis is extended, the waistband still has gathers andcaliper.

In one embodiment, the waistband is comprised of a laminate comprising anonwoven material and at least one elastic strand, wherein the nonwovenmaterial and the elastic strand(s) are combined under a first strain andthe waistband is attached to the article under an applied waistbandstrain. In one embodiment, the first strain, also referred to as theinstalled strand elongation, is greater than about 50%, greater thanabout 75%, greater than about 100%, greater than about 150%, greaterthan about 200%, greater than about 225%, greater than about 250%,greater than about 300%, greater than about 350%, greater than about375%. In one embodiment, the applied waistband strain, also referred toas the waistband strain is greater than about 25%, greater than about50%, greater than about 75%, greater than about 100%. In one embodiment,the difference between the first strain and the applied waistbandstrain, also referred to as Consolidation, is greater than about 0%,greater than about 65%, greater than about 75%, greater than about 100%,greater than about 150%, greater than about 200%, greater than about225%, greater than about 250%, greater than about 300%.

In one embodiment, the waistband has a Full Waistband Consolidationgreater than about 95%, greater than about 100%, greater than about125%, greater than about 150%, greater than about 175%, greater thanabout 200%.

In one embodiment, the waistband had an Extended Waistband Consolidationgreater than about 35%, greater than about 50%, greater than about 75%,greater than about 100%, greater than about 125%, greater than about175%.

In one embodiment, the waistband is attached near the waist edge. In oneembodiment, the waistband is attached within 20 mm of the waist edge. Inone embodiment, the waistband is attached flush with the waist edge(i.e., the waistband is coterminous with the waist edge). In oneembodiment, the waistband is present only at one waist edge. In oneembodiment, the waistband is present at both the first and secondwaistband edges.

The nonwoven material and the elastic strand(s) may be combined withadhesive, mechanical bonds, or any other forms of attachment known inthe art. The waistband may be attached to the article with adhesive,mechanical bonds, or any other forms of attachment known in the art.

In one embodiment, the relaxed caliper of the waistband is greater thanabout 1.60 mm, greater than about 2.00 mm, greater than about 2.25 mm,greater than about 2.50 mm.

In one embodiment, the extended caliper of the waistband is greater thanabout 0.80 mm, greater than about 1.00 mm, greater than about 1.25 mm.

Another object of the open form disposable absorbent articles detailedherein is to include a first waist region 36 with a stretchable frontwaist feature (e.g., first waistband 1000), wherein the first waistregion 36 is flexible and comfortable to wear, promotes continuouscontact with the wearer's body, and resists rolling, flipping orscrunching. Further, if the first waist region 36 of the open formdisposable absorbent articles detailed herein does roll, flip orscrunch, the first waist region 36 has a tendency to return to itsoriginal position in contact with the wearer's body.

As explained in the Background section above, previous known open formdisposable absorbent articles sometimes employ materials with a highstiffness in the front waist region in order to counteract the bendingand buckling forces exerted by a wearer's body. However, the increasedstiffness results in a front waist region which does not conform to thebody of the wearer as the body changes shape during use due to awearer's posture, breathing, food intake, etc., and therefore isuncomfortable for the wearer. Accordingly, in addition to promotingcontinuous contact with a wearer's body, the front waist assembly of theopen form disposable absorbent articles detailed herein may also have alow stiffness to promote comfort for the wearer.

Materials deform (e.g., bend, buckle) when sufficient force is applied,and the higher this force the more stiff a material is considered. Somematerials undergo permanent or semi-permanent deformation when the forceapplied to them exceeds their stiffness. Other materials reversiblydeform under a particular range of forces, and will attempt to return totheir original shape when the force is released (e.g., a spring). Theenergy that a material is able to utilize when returning to its originalshape is defined as the material's resiliency. Accordingly, a materialthat has a relatively low stiffness and relatively high resiliency isdesirable for utilization in a first waist region 36 of an open formdisposable absorbent article 20. In creating first waist regions 36which promote continuous contact with a wearer's body and resistrolling, flipping and/or scrunching, the first waist region may have aresiliency that is greater than about 5 mJ, greater than about 5.5 mJ,greater than about 6.0 mJ, greater than about 6.1 mJ, greater than about6.2 mJ, greater than about 6.3 mJ, greater than about 6.4 mJ, greaterthan about 6.5 mJ, greater than about 7.0 mJ, greater than about 7.5 mJ,greater than about 8.0 mJ, greater than about 8.5 mJ, greater than about9.0 mJ, greater than about 9.5 mJ, greater than about 10.0 mJ, greaterthan about 10.5 mJ, greater than about 11.0 mJ, greater than about 11.5mJ, greater than about 12.0 mJ, greater than about 12.5 mJ, greater thanabout 13.0 mJ, greater than about 13.5 mJ, greater than about 14.0 mJ,greater than about 14.5 mJ, or greater than about 15.0 mJ; and astiffness of less than about 11.0 N, less than about 10.0 N, less thanabout 9.0 N, less than about 8.0 N, less than about 7.0 N, less thanabout 6.0 N, less than about 5.0 N, or less than about 4.0 N. In someembodiments, it may be desirable for the first waist region to have aresiliency of between about 5.0 mJ and about 15.0 mJ, or between about5.0 mJ and about 10.0 mJ. In some embodiments, it may be desirable forthe first waist region to have a stiffness of between about 4.0 N and10.0 N, or between about 6.0 N and about 10.0 N. In some embodiments, itmay be desirable for the first waist region to have a resiliency ofgreater than about 5.0 mJ and a stiffness of less than about 10.0 N. Theresiliency and stiffness parameters are measured in the first waistregion as defined below in the Test Methods section. In order tocalculate the resiliency and stiffness of the first waist region 36, theopen form disposable absorbent article 20 is tested with a markedlocation 322 that is 15 mm inboard of the waist edge 14 of the firstwaist region 36. Thus, the resiliency and stiffness testing procedure isrun according to the First Waist Region Stiffness and First Waist RegionResiliency Method detailed below, with 15 mm of the first waist region36 hanging over the test edge 318 of the test surface 311 of the supportplatform 310.

In creating waist features which do not roll, flip and/or scrunch, itmay also be helpful to eliminate areas within the front waist of theproduct where the resiliency falls substantially below the resiliency ofthe surrounding areas. The first waist region 36 may include ninesections that run parallel to the waist edge 14 of the disposableabsorbent article. As illustrated in FIG. 11, within the first waistregion 36, the disposable absorbent articles detailed herein may includea first section 1, a second section 2, a third section 3, a fourthsection 4, a fifth section 5, a sixth section 6, a seventh section 7, aneighth section 8, and a ninth section 9. The first section is 10 mm inwidth, and each section after that is 5 mm in width. Accordingly, thefirst section 1 of first waist region 36 is the area between waist edge14 and a line 101 that is parallel to waist edge 14 that is 10 mminboard of waist edge 14. The second section 2 of first waist region 36is the area between the line 101 that is parallel to waist edge 14 thatis 10 mm inboard of waist edge 14, and a line 102 that is parallel towaist edge 14 that is 15 mm inboard of waist edge 14. The third section3 of first waist region 36 is the area between the line 102 that isparallel to waist edge 14 that is 15 mm inboard of waist edge 14, and aline 103 that is parallel to waist edge 14 that is 20 mm inboard ofwaist edge 14. The fourth section 4 of first waist region 36 is the areabetween the line 103 that is parallel to waist edge 14 that is 20 mminboard of waist edge 14, and a line 104 that is parallel to waist edge14 that is 25 mm inboard of waist edge 14. The fifth section 5 of firstwaist region 36 is the area between the line 104 that is parallel towaist edge 14 that is 25 mm inboard of waist edge 14, and a line 105that is parallel to waist edge 14 that is 30 mm inboard of waist edge14. The sixth section 6 of first waist region 36 is the area between theline 105 that is parallel to waist edge 14 that is 30 mm inboard ofwaist edge 14, and a line 106 that is parallel to waist edge 14 that is35 mm inboard of waist edge 14. The seventh section 7 of first waistregion 36 is the area between the line 106 that is parallel to waistedge 14 that is 35 mm inboard of waist edge 14, and a line 107 that isparallel to waist edge 14 that is 40 mm inboard of waist edge 14. Theeighth section 8 of first waist region 36 is the area between the line107 that is parallel to waist edge 14 that is 40 mm inboard of waistedge 14, and a line 108 that is parallel to waist edge 14 that is 45 mminboard of waist edge 14. The ninth section 9 of first waist region 36is the area between the line 108 that is parallel to waist edge 14 thatis 45 mm inboard of waist edge 14, and a line 109 that is parallel towaist edge 14 that is 50 mm inboard of waist edge 14.

In certain embodiments, the difference in resiliency between twoadjacent sections 1, 2, 3, 4, 5, 6, 7, 8, 9 is not more than about 60%of the average resiliency of all the sections 1, 2, 3, 4, 5, 6, 7, 8, 9,in the first waist region 36. Shown as a calculation: A Resiliencybetween adjacent sections=(Absolute Value of (Resiliency of asection−Resiliency of an adjacent section))/Resiliency average for allsections≤60%. In other embodiments, the difference in resiliency betweentwo adjacent sections 1, 2, 3, 4, 5, 6, 7, 8, 9 is not more than about40%, about 45%, about 50%, about 65%, about 70%, about 80%, about 90%,or about 100% of the average resiliency of all the sections 1, 2, 3, 4,5, 6, 7, 8, 9, in the first waist region 36. In addition to thedifference in resiliency between two adjacent sections of the firstwaist region 36, some embodiments of open form disposable absorbentproduct 20 also include a first waist region 36 stiffness of less thanabout 11.0 N, less than about 10.0 N, less than about 9.0 N, less thanabout 8.0 N, less than about 7.0 N, less than about 6.0 N, less thanabout 5.0 N, or less than about 4.0 N. Such stiffness is measured 15 mminboard of the waist edge 14 of the first waist region 36 (i.e., at line102 that separates section 2 from section 3). The resiliency parametersspecific to each section of first waist region 36 are measured asdefined below in the Test Methods section. In order to calculate theresiliency of the first section 1, the open form disposable absorbentarticle 20 is tested with a marked location 322 that is 10 mm inboard ofthe waist edge 14 of the first waist region 36. Accordingly, theresiliency and stiffness testing procedure is run according to the FirstWaist Region Stiffness and First Waist Region Resiliency Method detailedbelow, with 10 mm of the first waist region 36 hanging over the testedge 318 of the test surface 311 of the support platform 310. In orderto calculate the resiliency of the second section 2, the open formdisposable absorbent article 20 is tested with a marked location 322that is 15 mm inboard of the waist edge 14 of the first waist region 36.The testing of each subsequent section follows accordingly (thirdsection 3 is tested with a marked location 322 that is 20 mm inboard ofthe waist edge, fourth section 4 is tested with a marked location thatis 25 mm inboard of the waist edge, etc.).

Resiliency and stiffness are material properties that can change basedon the physical configuration or structure of a material as well as thecomposition of the material. One embodiment of the open form disposableabsorbent articles detailed herein includes a non-woven material whichgains resiliency through its three-dimensional structure. Corrugatingthe non-woven material may provide this three dimensional structure.Additionally, the following structural elements are believed to impactresiliency in nonwoven materials: thickness, density, basis weight,uniformity and/or regularity in the corrugations, fibers which arecurled (e.g., bi-component fibers which are curled), differential strainlamination, mechanical properties of the polymer, and the material'sability to non-plastically deform under strain.

As shown in FIG. 1, if the waistband is 25 mm or greater in thelongitudinal direction, the waist assembly 35 is the area of first waistregion 36 that is between waist edge 14 and a line 201 that is parallelto waist edge 14 that is 25 mm inboard of waist edge 14. If thewaistband is shorter than 25 mm in the longitudinal direction, the waistassembly 35 is defined as the area of the first waist region that isbetween the waist edge 14 and the inboard edge of the waistband. Withoutbeing bound by theory, when a waist assembly 35 of the first waistregion 36 of an open form disposable absorbent article is bent away fromthe wearer's body, the body-facing surface of the waist assembly 35attempts to travel over a longer path when compared to thegarment-facing surface, due to the radius of curvature being longer forthe body facing surfaced. The longer path of travel is due to thethickness of the materials comprising the waist assembly 35. Havingcorrugations in the waist assembly 35 can increase its effectivethickness. Accordingly, the body-facing surface of the waist assembly 35is placed in tension. Thicker materials in the waist assembly 35 (e.g.,higher basis weight) and/or deeper the corrugations lead to more tensionin the body-facing surface of the material. This tension causes thewaist assembly 35 to have a propensity to return to its original shape.Regular and consistent corrugations cause even more tension because suchcorrugations are more energetically stable. Conversely, irregularcorrugations may indicate that the waist region 35 has natural weakpoints or spots where tension stored in a waistband can be relieved.Reliving the tension stored in the waist assembly 35 may reduce theenergy available to return it to its upright state. In addition, theresiliency of the waist assembly 35 may be increased through waistbandconsolidation, as further detailed herein.

Further, curled fibers may act as tiny springs in the material of thewaist assembly 35. As the waist assembly 35 bends, the springs on thebody-facing surface extend, and the springs on the garment facingsurface are compressed. This compression/tension may return the materialto its original shape. In addition, differential strain may cause thewaist assembly 35 to bend in a particular direction (i.e., towards thebody) in order to relax the higher strain in the body facing surface. Asthe waist assembly 35 is bent away from the body, the body facingsurface is put under incrementally more strain than an equivalentsurface which was laminated at equal strain.

Corrugations are often difficult to create in inexpensive non-wovenmaterials. One method for creating such corrugations is to use a deepbond pattern in a relatively thick non-woven such that the bond patterncreates columns in the longitudinal direction waist assembly 35 of theabsorbent article. When such a non-woven is consolidated in the lateraldirection, the bond sites will tend to buckle while the unbonded siteswill tend to pucker up, creating corrugations. If the bonds are createdin a regular pattern, the corrugations will also tend to be regular.FIGS. 12A-D and 13A-D illustrate two non-limiting examples of non-wovenswith a deep continuous bond pattern that can be employed in waistassembly 35 and that include regular and uniform corrugations. FIG. 12illustrates a regular straight bond pattern in the flat nonwoven as showin FIG. 12A, and FIG. 13 illustrates a regular wavy bond pattern in theflat nonwoven as shown in FIG. 13A. FIGS. 12B and 13B illustrate crosssectional profiles of the bond patterns in the flat nonwovens of FIGS.12A and 13A. FIGS. 12C and 13C illustrate the cross sectional profilesof the bond patterns when the nonwovens are elastically contracted, thusforming regular corrugations. FIGS. 12D and 13D illustrate perspectiveviews of the of the bond patterns when the nonwovens are elasticallycontracted, thus forming regular corrugations. Other bond patterns arealso contemplated, as long as the bond patterns are consistent andtravel substantially the continuous longitudinal dimension of thewaistband material. Additional bond patterns may include zigzag bondlines, diagonal bond lines, or any other pattern where a line drawnlaterally across the waistband does not intersect any single bond linemore than once. As used herein, the term “bond line” refers to aplurality of sites on a substrate where the fibers of the substrate havebeen joined together. Joining can be accomplished through various meanssuch as thermal bonds, pressure bonds, ultrasonic welds, glue bonds, orthe like. The plurality of sites can be joined together to form the“line”. However, the term “line”, as used herein, can also describe aseries of discrete points or short lines closely spaced so as toeffectively approximate a line. Therefore, those skilled in art willrecognize that although a solid line bonding pattern is described, thebenefits of the present invention can similarly be achieved by closelyspaced points or discrete line segments which effectively approximate aline.

FIG. 14 is a photograph of a waist assembly that contains regular anduniform gathers. The waistband of FIG. 14 was constructed from a 30 gsmside-by-side bi-component polyethylene/polypropylene non-woven with awavy bond pattern (the details of the pattern can be found inUS2010298796). The bond in the bond pattern is about 1 mm wide, theunbonded region is about 2.5 mm wide, the wave amplitude is about 4 mm,and the wave frequency is about 0.04 mm⁻¹. The elastic installedelongation is 90%, and the applied waistband strain is 11%. FIG. 15 is aphotograph of a waist assembly that contains irregular gathers. Thewaistband of FIG. 15 was constructed from a 15 gsm side-by-sidebi-component polyethylene/polypropylene non-woven with a wavy bondpattern (the details of the pattern can be found in US2010298796). Thebond in the bond pattern is about 1 mm wide, the unbonded region isabout 2.5 mm wide, the wave amplitude is about 4 mm, and the wavefrequency is about 0.04 mm⁻¹. The elastic installed elongation is 90%,and the applied waistband strain is 11%. FIG. 16 is a photograph of awaist assembly that contains irregular gathers. The waistband of FIG. 16was constructed from a 10 gsm SMS non-woven with a bond patternconsisting of small dots. The elastic installed elongation is 90%, andthe applied waistband strain is 11%. All waistband adhesives are spiralglue.

More regular and consistent/uniform corrugations potentially yield moreresiliency to the waist assembly 35 of the first waist region 36. Tocreate more consistent corrugations, it may be advantageous to match thefrequency of the bond sites, the stiffness of the non-bonded material,and the desired amount of installed elongation. As one non-limitingexample, if the desired installed elongation level may be about 60% toabout 150% and the non-woven basis weight may be about 20 gsm to about75 gsm, a bond frequency of about 0.1 mm⁻¹ to about 2.0 mm⁻¹ may bedesirable. In other examples of the waist assembly 35 of the open formdisposable absorbent articles 20 detailed herein, the desired installedelongation level may be about 75% to about 115%, or about 80% to about100%; the non-woven basis weight may be about 20 gsm to about 50 gsm, orabout 25 gsm to about 45 gsm, or about 25 gsm to about 35 gsm, or about30 gsm; and a bond frequency may be about 0.1 mm⁻¹ to about 1.5 mm⁻¹, orabout 0.1 mm⁻¹ to about 1.0 mm⁻¹, or about 0.1 mm⁻¹ to about 0.75 mm⁻¹.In one particular embodiment, the waist assembly 35 may include awaistband that has an elastic installed elongation of about 90%, anon-woven basis weight of about 30 gsm, and a bond frequency of about0.5 mm⁻¹.

Further, it may also be important that such corrugations are presentwhen the product is configured to be worn. Many waistbands which mayappear corrugated in a relaxed state are actually laminated flat againstthe diaper chassis, thus there are no corrugations when the front of thediaper is stretched when being worn. Consolidating the waistband (asdescribed herein) prior to application to waist band assembly 35 is onemeans to ensure that corrugations are still present when the diaper isconfigured to be worn.

Another method for creating regular corrugations is to use glue or otherattachment means which create discretely spaced columns in thelongitudinal direction of the absorbent article. These attachment meanscan be used internally to assemble components of the stretch feature(e.g., to attach elastic strands to a non-woven material), or to attachthe stretch feature to another part of the absorbent article. Thismethod can also be used to create uniform gathers which run the entirelongitudinal length of the waistband assembly 35.

Regular corrugations are corrugations which are substantially evenlyspaced and sized. This helps ensure that forces are distributed evenlyacross the waist assembly 35. Also, since nonwovens are typically madein large webs with substantially regular properties across the web, andsince the corrugation size is dependent on the stiffness of this web,creating regular corrugations prevents any particular corrugation fromhaving sub-optimal strength by being differently sized than itsneighbors. Uniform corrugations are corrugations which are continuousfrom the waist edge 14 of the first waist region 36 to the bottom of thewaist assembly 35 without being broken, disrupted, or forked. Breaks,disruptions, and forks may indicate weak spots in the corrugationstructure.

In creating waist features which do not roll, flip and/or scrunch, itmay also be helpful to eliminate areas that allow hinge lines to formacross the front waist region 36, i.e., where bending is likely tooccur. Hinge lines can be created where materials have significantlylower bending strengths than the surrounding areas. Eliminating hingelines can be accomplished by adding significant stiffness to all theareas in the first waist region 36, but this can result in a first waistregion that is stiff enough to cause discomfort to the wearer. Hingelines can typically also occur at the lateral edge of a material orcomponent which is a portion of the first waist region 36. An example ofthis is at the bottom edge of the waistband in the first waist region36, or at the top edge of the absorbent assembly in the first waistregion 36. Another area where a hinge line can occur is at the top orbottom edges of the fastening system, particularly in systems withrectangular shaped fastening elements. The area where a given materialends (e.g., the lateral waistband edge) usually corresponds to an areaof thickness change of the first waist region 36. Without being bound bytheory, thickness is a key variable in the flexibility of materials, andan area where there is a significant thickness change can result in asignificant flexibility difference versus the adjacent areas. Thereforeit is desirable to create smooth flexibility transitions betweenmaterial edges that are less abrupt, to spread the change in flexibilityover a wider area. This can be accomplished effectively by ensuringthere is sufficient overlap between the edges of materials, and avoidingcomponents that co-terminate or have slight gaps.

In one embodiment, the open form disposable absorbent articles detailedherein include a first waist region, a second waist region, a crotchregion disposed between the first waist region and second waist region;a first waist edge and a second waist edge; at least one fastener in thesecond waist region; and at least one waistband in the first waistregion adjacent the first waist edge; a topsheet, a backsheet, and anabsorbent core disposed between the topsheet and backsheet; wherein thefirst waist region contains an overlap between the absorbent core andthe waistband. FIG. 19 shows a garment facing surface of an exemplaryopen form disposable absorbent article as disclosed herein. In FIG. 19,the waistband 1000 in the first waist region overlaps with absorbentcore 28 to form an overlap region 1002. As previously detailed, theabsorbent core 28 may comprise a core cover, a dusting layer, and a widevariety of liquid-absorbent materials commonly used in disposablediapers and other absorbent articles. In the illustrated embodiment, thelateral edge 1004 of the absorbent core 28 is inboard of the waist edge14 of the first waist region 26. The overlap region 1002 may create asmoother transition between the edge of the waistband 1000 and the edgeof the absorbent core 28, therefore spreading the change in flexibilityover a wider area and reducing bending/buckling occurrences.

In one non-limiting embodiment, the waistband extends 26 mm from thefirst waist edge, and the absorbent core is spaced 14 mm from the firstwaist edge, creating a 12 mm overlap region in the longitudinaldirection between the waistband and the absorbent core. In someembodiments, the overlap region ranges in the longitudinal directionfrom about 5 mm to about 25 mm, or from about 7.5 mm to about 20 mm, orfrom about 10 mm to about 15 mm. In some embodiments, overlap regionscan be about 2 mm, about 4 mm, about 6 mm, about 8 mm, about 10 mm,about 12 mm, about 14 mm, about 16 mm, about 18 mm, about 20 mm, about22 mm, about 24 mm, about 26 mm, about 28 mm or about 30 mm.

In another embodiment, the open form disposable absorbent articlesdetailed herein include a first waist region, a second waist region, acrotch region disposed between the first waist region and second waistregion; a first waist edge and a second waist edge; at least onefastener in the second waist region; at least one discrete landing zonein the first waist region; and at least one waistband in the first waistregion adjacent the first waist edge; wherein the first waist regioncontains an overlap between the discrete landing zone and the waistband.FIG. 18 shows a body facing surface of an exemplary open form disposableabsorbent article as disclosed herein. FIG. 17 shows a garment facingsurface of an exemplary open form disposable absorbent article asdisclosed herein. In FIG. 17, the waistband 1000 in the first waistregion overlaps with discrete landing zone 1001 to form an overlapregion 1002. In this illustrated embodiment, the lateral inboard edge1003 of discrete landing zone 1001 is not overlapped with the waistband1000. The overlap region 1002 may create a smoother transition betweenthe edge of the waistband 1000 and the edge of the discrete landing zone1001, therefore spreading the change in bending strength over a widerarea and reducing bending/buckling occurrences.

In one non-limiting embodiment, the waistband extends 26 mm from thefirst waist edge, and the discrete landing zone is spaced 14 mm from thefirst waist edge, thus creating a 12 mm overlap region in thelongitudinal direction between the waistband and discrete landing zone.In some embodiments, the overlap region ranges in the longitudinaldirection from about 5 mm to about 25 mm, or from about 7.5 mm to about20 mm, or from about 10 mm to about 15 mm. In some embodiments, overlapregions can be about 2 mm, about 4 mm, about 6 mm, about 8 mm, about 10mm, about 12 mm, about 14 mm, about 16 mm, about 18 mm, about 20 mm,about 22 mm, about 24 mm, about 26 mm, about 28 mm or about 30 mm.

Another object of the disposable absorbent articles detailed herein isto deliver an integrated leg gasketing system and front/back waistbandfeature that provides extra leakage protection around the perimeter ofthe article. Thus, one embodiment of the disposable absorbent articlesdetailed herein is directed to “360 Leakage Protection” which provides acommon leg gasketing system and waistband with similar constructionhaving similar gather counts. Additional embodiments may include leggasketing systems and waistbands that overlap or have similar tints,textures, bond patterns, colors, or other visual cues. FIG. 3 depicts anembodiment having gathers in both the waist assemblies and leg gasketingsystem.

In one embodiment, the waistband overlaps the leg gasketing system inthe first waist region. In one embodiment, the waistband overlaps theleg gasketing system in the second waist region. In one embodiment, thewaistband overlaps the leg gasketing system in both the first waistregion and the second waist region. In one embodiment, the waistbandlaterally terminates within the span of the leg gasketing system in thefirst waist region, thus partially overlapping the leg gasketing systemin the first waist region. In one embodiment, the waistband laterallyterminates within the span of the leg gasketing system in the secondwaist region, thus partially overlapping the leg gasketing system in thesecond waist region. In one embodiment, the waistband laterallyterminates within the span of the leg gasketing system in the firstwaist region and the second waist region, thus partially overlapping theleg gasketing system in the first waist region and the second waistregion.

In one embodiment, the disposable absorbent article comprises awaistband and a leg gasketing system, as described herein, wherein theleg gasketing system has a first gather count and the waistband has asecond gather count such that the ratio of the first gather count to thesecond gather count is greater than about 0.5, greater than about 0.75,less than about 1.25, less than about 1.50. In one embodiment, the ratioof the first gather count to the second gather count is about 1.00. Inone embodiment, the ratio of the first gather count to the second gathercount is from about 0.75 to about 1.25. In one embodiment, the ratio ofthe first gather count to the second gather count is from about 0.75 toabout 1.25, when the leg gasketing system gather count is greater thanabout 13. In one embodiment, the ratio of the first gather count to thesecond gather count is from about 0.75 to about 1.25, when the waistbandgather count is greater than about 12. In one embodiment, the ratio ofthe first gather count to the second gather count is from about 0.75 toabout 1.25, when the absorbent article is a taped-type product.

In one embodiment, both of the waistband and leg gasketing systemcomprise elastic strands; in one embodiment, the waistband compriseselastic strands; in one embodiment, both the waistband and leg gasketingsystem comprise the same type of stretch material and/or laminatestructure.

In one embodiment, the waistband has greater than about 10 gathers per30 mm section, greater than about 12 gathers per 30 mm section. In oneembodiment, the leg gasketing system has greater than about 10 gathersper 30 mm section, greater than about 12 gathers per 30 mm section.

In one embodiment, the waistband is present in the first waist edge andthe second waist edge and the leg gasketing system is present in thefirst longitudinal edge and the second longitudinal edge.

The absorbent article 20 may include a leg gasketing system 70 asdescribed in U.S. Patent Publication Nos. US 2012/0277713A1 and US2012/0277702A1, both filed on Apr. 29, 2011. FIGS. 4 and 5 depictschematic cross section views of exemplary leg gasketing systems. Theleg gasketing system 70 may comprise an inner barrier leg cuff 71comprising an inner cuff folded edge 72 and an inner cuff material edge73. The leg gasketing system 70 may further comprise an outer cuff 74comprising an outer cuff folded edge 75 and an outer cuff material edge76.

In one embodiment, the leg gasketing system 70 comprises one web ofmaterial. An embodiment having one web of material may provide a costadvantage over embodiments having more than one web of material.Further, an embodiment having one web of material may have fewer leaks,as there are no holes created by bonding more than one web of material.Also, an embodiment having one web of material may be more aestheticallypleasing, as few mechanical bonds are visible.

In one embodiment, the leg gasketing system 70 has an inner barrier legcuff 71 comprised of an inner cuff folded edge 72 and an inner cuffmaterial edge 73. The leg gasketing system 70 may further comprise anouter cuff 74 comprising an outer cuff folded edge 75 and an outer cuffmaterial edge 76. In one embodiment, the web of material is foldedlaterally inward to form the outer cuff folded edge 75 and foldedlaterally outward to form the inner cuff folded edge 72. In oneembodiment, the leg gasketing system 70 extends from the first waistedge 36 to the second waist edge 38 and is joined to the topsheet 24and/or backsheet 26 between the inner cuff folded edge 72 and the outercuff folded edge 75 in the crotch region 37. In one embodiment, theouter cuff material edge 76 is disposed laterally inboard the inner cuffmaterial edge 73.

In one embodiment, the outer leg cuff 74 comprises elastic members 77positioned in a lateral array between the outer cuff folded edge 75 andouter cuff material edge 76; the outer leg cuff 74 optionally comprisesat least two elastic members 77, at least three elastic member 77, atleast four elastic members 77, at least five elastic members 77, atleast six elastic members 77. In one embodiment, the elastic members 77may be disposed between the outer cuff folded edge 75 and the inner cuffmaterial edge 73.

In one embodiment, the inner barrier leg cuff 71 comprises an array ofelastic members 78 in the area of the inner cuff folded edge 72; theinner barrier leg cuff 71 optionally comprises at least one elasticmember 78, at least two elastic members 78, at least three elasticmembers 78, at least four elastic members 78, at least five elasticmembers 78. In one embodiment, the elastic members 78 may be disposedbetween the inner cuff folded edge 72 and the outer cuff material edge76.

In one embodiment, the leg gasketing system 70 has an inner barrier legcuff 71 comprised of an inner cuff folded edge 72 and an inner cuffmaterial edge 73. The leg gasketing system 70 may further comprise anouter cuff 74 comprising an outer cuff folded edge 75 and an outer cuffmaterial edge 76. The leg gasketing system may comprise a first materialcomprising the inner barrier leg cuff 71 and a second materialcomprising the outer cuff 74. The first and second material may overlapand be joined together along a longitudinal edge of each material by anysuitable bonding means. In one embodiment, the web of material is foldedlaterally inward to form the outer cuff folded edge 75 and foldedlaterally outward to form the inner cuff folded edge 72. In oneembodiment, the proximal edges of the outer cuff 74 are coterminous.

One advantage of the leg gasketing system 70 of the disposable absorbentarticles detailed herein is that when a substantially liquid-imperviousmaterial is used in construction of the cuff, the polymeric film layermay be narrowed or not present at all, resulting in more cost effectivedesigns. Utilizing adhesive technologies that are more reliablyprocessed results in more reliable performance and creates substantiallyliquid impervious seals. This technology enables narrowing the filmlayer to be only slightly wider than the absorbent core by reducing theneed for redundant seals.

In one embodiment of the disposable absorbent articles detailed herein,the backsheet polymeric film is less than about 50 mm wider than theabsorbent core; optionally less than about 40 mm wider, less than about30 mm wider. In one embodiment, the backsheet polymeric film is at leastabout 20 mm more narrow than the chassis width; optionally at leastabout 40 mm more narrow than the chassis width; optionally at leastabout 60 mm more narrow than the chassis width; optionally at leastabout 80 mm more narrow than the chassis width; optionally at leastabout 100 mm more narrow than the chassis width; optionally at leastabout 120 mm more narrow than the chassis width.

In one embodiment of the disposable absorbent articles detailed herein,an opacity strengthening patch 80 may be included. The opacitystrengthening patch 80 is an additional layer of material. The opacitystrengthening patch 80 may be connected to the leg gasketing system 70,the polymeric film layer, or the backsheet 26. The opacity strengtheningpatch 80 may be disposed between the backsheet 26 and leg gasketingsystem 70 in either the first waist region 36, the second waist region38, or both the first waist region 36 and the second waist region 38 ofthe article; the opacity strengthening patch 80 may overlap at least oneof the leg gasketing system 70 or the polymeric film layer. The opacitystrengthening patch 80 may be attached to one or both of the leggasketing system 70 or the polymer film layer using any suitable meanssuch as glue, mechanical bonds, thermal bonds, or the like, so thatloads generated during the application process or during wear can betransferred from the waist edge of the article to the leg gasketingsystem 70 and/or the polymeric film layer. The opacity strengtheningpatch is useful in providing the strength needed to prevent the articlefrom extending excessively during application and wearing; it also mayprovide opacity at the sides and waist to prevent the skin of the userfrom showing through the article. Thus, the patch 80 may be located atany portion of the chassis where strength and opacity is desirable.Materials suitable to act as the opacity strengthening patch includematerials having a basis weight of at least about 10 gsm, at least about15 gsm, at least about 25 gsm. An opacity strengthening patch usefulherein may exhibit the following tensile properties in the crossdirection: at 2% engineering strain for a 1 inch wide sample, 0.4N; at5% engineering strain for a 1 inch wide sample, 1.25N; at 10%engineering strain for a 1 inch wide sample, 2.5N. One opacitystrengthening patch useful herein is available from Pegas, Znojmo, CZ,as supplier number 803968.

In one embodiment, the material of the leg gasketing system 70 is madefrom a substantially liquid impervious material. The material may beselected from the group consisting of an SMS nonwoven, SMMS nonwovenmaterial, or a nonwoven component layer comprising “N-fibers”. In someembodiments, the leg gasketing material does not include a polymericfilm in its construction.

Various nonwoven fabric webs may comprise spunbond, meltblown, spunbond(“SMS”) webs comprising outer layers of spunbond thermoplastics (e.g.,polyolefins) and an interior layer of meltblown thermoplastics. In oneembodiment of the disposable absorbent articles detailed herein, the leggasketing cuff 70 comprises a nonwoven component layer having finefibers (“N-fibers”) with an average diameter of less than 1 micron (an“N-fiber layer”) may be added to, or otherwise incorporated with, othernonwoven component layers to form a nonwoven web of material. In someembodiments, the N-fiber layer may be used to produce a SNS nonwoven webor SMNS nonwoven web, for example. N-fibers are further discussed in WO2005/095700 and U.S. patent application Ser. No. 13/024,844.

In one embodiment, an absorbent article includes an absorbent core 28that is substantially cellulose free, as described in U.S. Pat. Nos.7,750,203; 7,744,576, and U.S. Patent Publication No. 2008/0312617A1.Cross-sectional views of examples of suitable absorbent cores areschematically represented in FIGS. 6-8. In one embodiment, an absorbentcore 28 comprises first and second layers of material 281, 282 and anabsorbent material 283 disposed between the first and second layers 281,282. In one embodiment the first and second layers of material can be afibrous material chosen from at least one of a nonwoven fibrous web, awoven fibrous web and a layer of thermoplastic adhesive material.Although the first and second layers can be made of a same material, inone embodiment, the first layer 281 is a nonwoven fibrous web and thesecond layer 282 is a layer of thermoplastic adhesive material. Anonwoven fibrous web 281 can include synthetic fibers, such asmono-constituent fibers of PE, PET and PP, multi-constituent fibers suchas side by side, core/sheath or island in the sea type fibers. Suchsynthetic fibers may be formed via a spunbonding process or ameltblowing process. The nonwoven fibrous web 281 may include a singlelayer of fibers but it may also be advantageous to provide the nonwovenweb with multiple layers of fibers such as multiple layers of spunbondfibers, multiple layers of meltblown fibers or combinations ofindividual layer(s) of spunbond and meltblown fibers. In one embodiment,the nonwoven web 281 can be treated with an agent (such as a surfactant)to increase the surface energy of the fibers of the web. Such an agentrenders the nonwoven web more permeable to liquids such as urine. Inanother embodiment, the nonwoven web can be treated with an agent (suchas a silicone) that lowers the surface energy of the fibers of thenonwoven web. Such an agent renders the nonwoven web less permeable toliquids such as urine.

The first layer 281 comprises a first surface 2811 and a second surface2812 and at least regions 2813 of the first surface are in direct facialrelationship with a significant amount of absorbent material 283. In oneembodiment an absorbent material is deposited on the first surface 2811in a pattern to form regions 2813 on the first layer 281, which are indirect facial relationship with a significant amount of absorbentpolymer material 283 and regions 2814 on the first web that are infacial relationship with only an insignificant amount of absorbentmaterial. By “direct facial relationship with a significant amount ofabsorbent material” it is meant that some absorbent material isdeposited on top of the regions 2813 at a basis weight of at least 100g/m², at least 250 g/m² or even at least 500 g/m². The pattern mayinclude regions that all have the same shape and dimensions (i.e.projected surface area and/or height). In the alternative the patternmay include regions that have different shape or dimensions to form agradient of regions.

In one embodiment, the second layer 282 is a layer of a thermoplasticadhesive material. “Thermoplastic adhesive material” as used herein isunderstood to mean a polymer composition from which fibers are formedand applied to the absorbent material with the intent to immobilize theabsorbent material in both the dry and wet state. Non-limiting examplesof thermoplastic adhesive material may comprise a single thermoplasticpolymer or a blend of thermoplastic polymers. The thermoplastic adhesivematerial may also be a hot melt adhesive comprising at least onethermoplastic polymer in combination with other thermoplastic diluentssuch as tackifying resins, plasticizers and additives such asantioxidants. In certain embodiments, the thermoplastic polymer hastypically a molecular weight (Mw) of more than 10,000 and a glasstransition temperature (Tg) usually below room temperature or −6°C.>Tg<16° C. In certain embodiments, typical concentrations of thepolymer in a hot melt are in the range of about 20 to about 40% byweight. Exemplary polymers are (styrenic) block copolymers includingA-B-A triblock structures, A-B diblock structures and (A-B)n radialblock copolymer structures wherein the A blocks are non-elastomericpolymer blocks, typically comprising polystyrene, and the B blocks areunsaturated conjugated diene or (partly) hydrogenated versions of such.The B block is typically isoprene, butadiene, ethylene/butylene(hydrogenated butadiene), ethylene/propylene (hydrogenated isoprene),and mixtures thereof. Other suitable thermoplastic polymers that may beemployed are metallocene polyolefins, which are polymers prepared usingsingle-site or metallocene catalysts. In exemplary embodiments, thetackifying resin has typically a Mw below 5,000 and a Tg usually aboveroom temperature, typical concentrations of the resin in a hot melt arein the range of about 30 to about 60% by weight, and the plasticizer hasa low Mw of typically less than 1,000 and a Tg below room temperature,with a typical concentration of about 0 to about 15%.

The thermoplastic adhesive material 282 can be disposed substantiallyuniformly within the absorbent material 283. In the alternative, thethermoplastic adhesive material 282 can be provided as a fibrous layerdisposed on top of the absorbent material 283 and the regions 2814 ofthe first surface 2811 that are in facial relationship with only aninsignificant amount of absorbent material. In one embodiment, athermoplastic adhesive material is applied at an amount of between 1 and20 g/m², between 1 and 15 g/m² or even between 2 and 8 g/m². Thediscontinuous deposition of absorbent material on the first layer 281imparts an essentially three-dimensional structure to the fibrous layerof thermoplastic material 282. In other words, the layer ofthermoplastic adhesive material follows the topography resulting fromthe absorbent material 283 deposited on the first nonwoven fibrous web281 and the regions 2814 that only include insignificant amounts ofabsorbent material. Without intending to be bound by any theory, it isbelieved that the thermoplastic adhesive materials disclosed hereinenhance immobilization of the absorbent material in a dry and wet state.

In one embodiment, the absorbent core 28 may further comprise a secondlayer of a nonwoven fibrous material 284. This second layer may beprovided of the same material as the nonwoven fibrous layer 281, or inthe alternative may be provided from a different material. It may beadvantageous for the first and second nonwoven fibrous layers 281, 284to be different in order to provide these layers with differentfunctionalities.

The regions 2813 may have any suitable shape in the x-y dimension of theabsorbent core. In one embodiment, the regions 2813 form a pattern ofdisc that are spread on the first surface of the first web 281. In oneembodiment, the regions 2813 form a pattern of longitudinal “strips”that extend continuously along the longitudinal axis of the absorbentcore (i.e. along the y dimension). In an alternative embodiment, thesestrips may be are arranged to form an angle of at between 10 and 90degrees, between 20 and 80 degrees, between 30 and 60 degrees, or even45 degrees relative to the longitudinal axis of the absorbent article.

In one embodiment, the second nonwoven layer 284 has a first surface2841 and a second surface 2842 and an absorbent material 283 applied toits first surface 2841 in order to form a pattern of regions 2843 thatare in direct facial relationship with a significant amount of absorbentmaterial 283 and regions 2844 on the first surface 2841 that are infacial relationship with only an insignificant amount of absorbentmaterial as previously discussed. In one embodiment, a thermoplasticadhesive material 285 may further be applied on top of the secondnonwoven layer 284 as previously discussed in the context of the firstweb/absorbent material/thermoplastic adhesive material composite. Thesecond nonwoven layer 284 may then be applied on top of the firstnonwoven layer 281. In one embodiment, the pattern of absorbent materialpresent on the second nonwoven layer 284 may be the same as the patternof absorbent material present on the first nonwoven layer 281. Inanother embodiment, the patterns of absorbent material that are presenton the first and second nonwoven layers are different in terms of atleast one of the shape of the regions, the projected surface areas ofthe regions, the amount of absorbent material present on the regions andthe type of absorbent material present on the regions.

The absorbent core 28 may also comprise an auxiliary adhesive which isnot illustrated in the figures. The auxiliary adhesive may be depositedon at least one of or even both the first and second nonwoven layers281, 284 before application of the absorbent material 283 in order toenhance adhesion of the absorbent material as well as adhesion of thethermoplastic adhesive material 282, 285 to the respective nonwovenlayers 281, 284. The auxiliary adhesive may also aid in immobilizing theabsorbent material and may comprise the same thermoplastic adhesivematerial as described hereinabove or may also comprise other adhesivesincluding but not limited to sprayable hot melt adhesives, such as H.B.Fuller Co. (St. Paul, Minn.) Product No. HL-1620-B. The auxiliaryadhesive may be applied to the nonwoven layers 281, 284 by any suitablemeans, but according to certain embodiments, may be applied in about 0.5to about 1 mm wide slots spaced about 0.5 to about 2 mm apart.Non-limiting examples of suitable absorbent material 283 includeabsorbent polymer material such as cross linked polymeric materials thatcan absorb at least 5 times their weight of an aqueous 0.9% salinesolution as measured using the Centrifuge Retention Capacity test (Edana441.2-01). In one embodiment, the absorbent material 283 is absorbentpolymer material which is in particulate form so as to be flowable inthe dry state.

EXAMPLES

Differential Contraction

Front Back Waist Front Waist Back Front-to- Relaxed Stretched FrontRelaxed Stretched Back Back Delta Chassis Chassis Chassis ChassisChassis Chassis in Chassis Width Width Contraction Width WidthContraction Contraction (mm) (mm) (%) (mm) (mm) (%) (%) Products RCFWECFW FCC RCBW ECBW BCC Delta CC Anerle 294 330 10.91 296 332 10.84 0.1Diaper (1) Parents 251 286 12.24 247 288 14.24 2.0 Choice Diaper (2)Moony 202 232 12.93 197 238 17.23 4.3 Diaper (3) Huggies 296 340 12.94299 335 10.75 2.2 Baby Steps (4) Huggies 251 270 6.91 231 270 14.34 7.4Supreme (5) Drypers (6) 300 350 14.29 284 332 14.46 0.2 (1) Anerle TapedDiaper from Philippines, Size L (9-13 kg), SKU 90324495220, Lot 20121009WP071157C9236; green foam sandwiched waistband (2) Parents Choice TapedDiaper (2) from North America, Lot 9344 M02 1759 S-1855; white foamsandwiched waistband (3) Moony Taped Diaper from Japan, Lot 910193071;green foam sandwiched waistband (4) Huggies Baby Steps US, 1991, Size 4,Lot 3U251910248; white foam sandwiched waistband in blue film (5)Huggies Supreme 2001, Size 4, Lot NM127501F0755; green nonwovenwaistband with small denier elastic strands in white film (6) Drypers,US, Size Large, 9/8/1998; white foam sandwiched waistband white film

Front Back Waist Front Waist Back Front-to- Relaxed Stretched FrontRelaxed Stretched Back Back Delta Chassis Chassis Chassis ChassisChassis Chassis Chassis Width Width Contraction Width Width ContractionContraction (mm) (mm) (%) (mm) (mm) (%) (%) Examples RCFW ECFW FCC RCBWECBW BCC Delta CC A 171 212.2 24.1 160 212.4 32.8 8.7 B 175.2 212.6 21.3165.2 212.6 28.7 7.3 C 179.6 212.6 18.4 166.2 212.6 27.9 9.5 D 179.4212.4 18.4 164.2 212.8 29.6 11.2 E 191.2 212.4 11.1 163.6 212.4 29.818.7 F 184.6 212.2 15.0 170.6 212.6 24.6 9.7 G 199.4 212.2 6.4 163.6212.6 30.0 23.5 H 192.4 212.6 10.5 165 213 29.1 18.6 I 201.6 212.4 5.4165 212.4 28.7 23.4 J 208.8 212.8 1.9 164.2 212.8 29.6 27.7 A—InstalledElongation: 150%; Waistband Strain: 150%; Delta Front/Back InstalledElongation: 0 B—Installed Elongation: 200%; Waistband Strain: 200%;Delta Front/Back Installed Elongation: 0 C—Installed Elongation: 150%;Waistband Strain: 130%; Delta Front/Back Installed Elongation: 20D—Installed Elongation: 200%; Waistband Strain: 180%; Delta Front/BackInstalled Elongation: 20 E—Installed Elongation: 150%; Waistband Strain:110%; Delta Front/Back Installed Elongation: 40 F—Installed Elongation:200%; Waistband Strain: 160%; Delta Front/Back Installed Elongation: 40G—Installed Elongation: 150%; Waistband Strain: 100%; Delta Front/BackInstalled Elongation: 50 H—Installed Elongation: 200%; Waistband Strain:140%; Delta Front/Back Installed Elongation: 60 I—Installed Elongation:200%; Waistband Strain: 120%; Delta Front/Back Installed Elongation: 80J—Installed Elongation: 200%; Waistband Strain: 100%; Delta Front/BackInstalled Elongation: 100Consolidation

Extended Relaxed Total Full Extended Relaxed Extended Length LengthLength Waistband Waistband Caliper Caliper CEL RWL EWL ConsolidationConsolidation Products (mm) (mm) (mm) (mm) (mm) (%) (%) Huggies Snug &0.91 0.55 237 172 273 59 −14 Dry (7) Huggies Little 1.08 0.61 223 155241 56 −14 Movers (8) Huggies 1.45 0.70 220 131 253 93 33 Overnight (9)K 1.64 0.40 205 125 201 60 −1 L 2.24 0.71 208 132 286 116 53 M 2.40 1.04203 130 340 162 98 N 2.54 1.01 205 131 386 195 131 O 2.22 1.29 205 126425 237 176 (7) Huggies Snug & Dry, size 4; Lot No. BI 103108B (8)Huggies Little Movers, size 3; Lot No. BI 024610B (9) Huggies Overnight,size 4; Lot No. PA 027104F K—75% Installed Elongation and 75% WaistbandStrain L—150% Installed Elongation and 75% Waistband Strain M—225%Installed Elongation and 75% Waistband Strain N—300% InstalledElongation and 75% Waistband Strain O—375% Installed Elongation and 75%Waistband Strain360 Leakage Protection

Average Leg Ratio of Leg Gasketing Gasketing System System AverageGather Count to Gather Waistband Waistband Gather Products Count GatherCount Count P 20.7 22.2 0.9 Q 21.2 21.2 1.0 R 16.7 18.2 0.9 Huggies BabySteps (4) 23.2 12.5 1.9 Huggies Supreme (5) 17.0 24.0 0.7 Anerle Diaper(1) 20.0 16.0 1.3 Parent Choice (2) 20.0 15.5 1.3 Moony Diaper (3) 12.511.2 1.1 P—150% Installed Elongation, 75% Waistband Strain R—150%Installed Elongation, 75% Waistband Strain Q—150% Installed Elongation,75% Waistband StrainStiffness and Resiliency for First Waist Region

Resiliency Products Stiffness (N) (mJ) S 7.6 6.5 T 2.2 1.3 U 11.9 16.1 V2.5 0.8 W 3.5 4.7 X 3.6 1.8S—Exemplary First Waist Region with a waistband of the followingconstruction: A 30 gsm side-by-side bi-componentpolyethylene/polypropylene non-woven with a wavy bond pattern (thedetails of the pattern can be found in US2010298796). The bond is about1 mm wide, the unbonded region is about 2.5 mm wide, wave amplitude isabout 4 mm, and wave frequency is about 0.04 mm⁻¹. Elastic installedelongation is 90%, and applied waistband strain is 11%. All waistbandadhesives are spiral glue.T—Typical First Waist Region with a waistband of the followingconstruction: A 10 gsm SMS non-woven with a bond pattern consisting ofsmall dots. Elastic installed elongation is 90%, and Applied WB Strainis 11%. All waistband adhesives are spiral glue.U—Stiff First Waist Region with a waistband of the followingconstruction: A 45 gsm side-by-side bi-component polyethylene/polyamidenon-woven with through-air bonding (no bond pattern). Elastic installedelongation is 90%, and applied waistband strain is 11%. All waistbandadhesives are spiral glue.V—Foam First Waist Region is from a size 4 Mamy Poko Boy/Girl tapeddiaper from ChinaW—Intermediate First Waist Region with a waistband of the followingconstruction: A 24 gsm highloft through-air bonded PE/PET (no bondpattern). Elastic installed elongation is 90%, and applied waistbandstrain is 11%. All waistband adhesives are spiral glue.X—Low Resiliency First Waist Region with a waistband of the followingconstruction: A 15 gsm side-by-side bi-component polyethylene/polyamidenon-woven with a wavy bond pattern (the details of the pattern can befound in US2010298796). The bond is about 1 mm wide, the unbonded regionis about 2.5 mm wide, wave amplitude is about 4 mm, and wave frequencyis about 0.04 mm⁻¹. Elastic installed elongation is 90%, and appliedwaistband strain is 11%. All waistband adhesives are spiral glue.Maximum Difference in Resiliency Between Two Adjacent Sections

Maximum Δ Resiliency Between Two Adjacent Products Stiffness (N)Sections (%) S 7.6 41.4 T 2.2 149.3 U 11.9 47.1 V 2.5 428.6 W 3.5 108.6X 3.6 254.3 S—Exemplary First Waist Region (same as Product S above inthe Stiffness and Resiliency data) T—Typical First Waist Region (same asProduct T above in the Stiffness and Resiliency data) U—Stiff FirstWaist Region (same as Product U above in the Stiffness and Resiliencydata) V—Foam First Waist Region (same as Product V above in theStiffness and Resiliency data) W—Intermediate First Waist Region (sameas Product W above in the Stiffness and Resiliency data) X—LowResiliency First Waist Region (same as Product X above in the Stiffnessand Resiliency data)Corrugation Regularity in the Waist Assembly

Gather Average Spacing Gather Standard Percentage less Spacing Deviationthan 1 mm from Products (mm) (mm) Average (%) Y 2.77 0.52 95.5 Z 3.671.23 63.3 Y—Exemplary First Waist Region with a waistband of thefollowing construction: A 30 gsm side-by-side bi-componentpolyethylene/polypropylene non-woven with a wavy bond pattern (thedetails of the pattern can be found in US2010298796). The bond is about1 mm wide, the unbonded region is about 2.5 mm wide, wave amplitude isabout 4 mm, and wave frequency is about 0.04 mm⁻¹. Elastic installedelongation is 90%, and applied waistband strain is 11%. All waistbandadhesives are spiral glue. Z—Typical First Waist Region with a waistbandof the following construction: A 10 gsm SMS non-woven with a bondpattern consisting of small dots. Elastic installed elongation is 90%,and applied waistband strain is 11%. All waistband adhesives are spiralglue.Corrugation Uniformity in the Waist Assembly

Percentage of No. of Complete No. of Broken Gathers that are ProductsGathers Gathers Complete (%) Y 40 8 83.3 Z 10 22 31.3 Y—Exemplary FirstWaist Region (same as Product Y above in the Corrugation Regularitydata) Z—Typical First Waist Region (same as Product Z above in theCorrugation Regularity data)Test MethodsChassis Contraction Method

The chassis contraction is measured using a calibrated ruler capable ofmeasuring to ±1 mm, (traceable to National standards such as NIST), anda force gauge capable of measuring an applied force of 500 g accuratelyto ±0.5 g (a suitable gauge is the Chatillon DFS series, available fromAmetek, Largo, Fla.). A spring loaded clamp, with contact faces 60 mmwide by 10 mm deep, is attached to the force gauge to hold the testarticle. All testing is performed in a room maintained at about 23±2° C.and about 50±2% relative humidity. All samples were conditioned for 2hours before testing at about 23±2° C. and about 50±2% relativehumidity.

For this measure the chassis is identified as the portion of the articlewith contiguous back sheet and does not include any attached tabs orattached elastic tabs/ears. Unfold the absorbent article taking care notto stretch the waist features. Place it on a horizontal bench surfacewith the back sheet facing the bench and the top sheet facing upward. Ifpresent, unfold and lie flat any tabs or ears attached to the back halfof the article. Identify the back waist feature of the article. With thearticle flat against the bench, lay the calibrated ruler along thearticle aligning it with the lateral midline of the waist feature.Measure the lateral distance from the right distal edge of the chassisto the left distal edge of the chassis and record to the nearest 1 mm.This is the Relaxed Back Chassis Width (RBCW).

Attach the force gauge to the right distal edge of the chassis. Asattached, the force gauge is oriented to pull from left to right. Thegrip faces are parallel to the longitudinal axis of the article,centered at the lateral midline of the waist feature, with 3 mm of thechassis within the grip faces.

Adhere a piece of 2-sided adhesive tape 50 mm in width by 900 mm long tothe bench. Hold the article with the back sheet directed toward thetaped surface with the back waist parallel to the long dimension of thetape. Align the lateral midline of the waist feature with the lateralmidline of the tape strip. Secure the first 3 mm of the left chassisedge to the adhesive tape. Using the force gauge, extend the back waistto an applied force of 500 g. Next, lower the article and adhere thearticle's back waist to the adhesive tape across the lateral width ofthe chassis. Remove the force gauge from the chassis. Lay the ruleracross the article aligning it along the lateral midline of the waistfeature. Measure the lateral distance from the right distal edge of thechassis to the left distal edge of the chassis and record to the nearest1 mm. This is the Extended Back Chassis Width (EBCW).

Repeat this measure in like fashion for the front waist feature of thearticle to determine the Relaxed Front Chassis Width (RFCW) and theExtended Front Chassis Width (EFCW). Calculate the Chassis Contractionsas follows:% Back Chassis Contraction (% BCC)=(EBCW−RBCW)/EBCW×100%Front Chassis Contraction (% FCC)=(EFCW−RFCW)/EFCW×100Front-to-Back Delta Chassis Contraction=absolute value of (% BCC−% FCC)Waist Feature Calipers

Calipers were performed using an Ono Sokki digital caliper (GS-503Linear Gauge Sensor with DG-3610 Digital Gauge, Ono Sokki Co, Japan)capable of measuring to 0.01 mm. The foot diameter is 1 cm and theapplied pressure is 0.5 psi. Readings are taken after a residence timeof 5 sec. Linear measurements are made using a calibrated ruler capableof measuring to ±1 mm (traceable to National standards such as NIST). Astainless steel plate, uniformly 1.5 mm thick±0.1 mm, 20 cm wide and 40cm long is used for mounting the extended waist. All testing isperformed in a room maintained at about 23±2° C. and about 50±2%relative humidity. All samples are conditioned for 2 hours beforetesting at about 23±2° C. and about 50±2% relative humidity.

Relaxed Waist Calipers

Unfold an absorbent article taking care not to stretch the waistfeatures. Place it on a horizontal bench surface with the back sheetfacing the bench and the top sheet facing upward. If present, unfold andlie flat any tabs or ears attached to the back half of the article.Identify the back waist feature of the article. Using a calibrated rulermeasure the lateral width of the waist feature along its longitudinalmidline. This is the Relaxed Length of the waist feature (RWL) Mark thewaist feature along its midline at 50% of its lateral width. This iswaist site 1 (WS1). Measure and mark two more sites, the first 1.5 cm tothe left of the 50% mark (WS2) and the second 1.5 cm to the right of the50% mark (WS3).

Place the caliper on the anvil and zero the digital controller. Placethe article on the anvil, with the top sheet facing upward, and use thecaliper to measure the thickness at WS1, WS2, and WS3. Report to thenearest 0.01 mm as the Relaxed Waist Caliper RWC1, RWC2, and RWC3respectively.

Using a cryogenic freeze spray (available as CytoFreeze, ControlCompany, TX) gently remove the elastic feature from the article. Placethe article on the anvil, with the top sheet facing upward, and use thecaliper to measure the thickness of the article corresponding to WS1,WS2, and WS3. Report to the nearest 0.01 mm as Relaxed Back SheetCaliper RBC1, RBC2, RBC3 respectively.

Calculate the Waist Feature Caliper as:Relaxed Waist Feature Caliper=[(RWC1−RBC1)+(RWC2−RBC2)+(RWC3−RBC3)]/3.

Repeat this procedure for three identical articles and report as theaverage to the nearest 0.01 mm.

Extended Waist Calipers

Unfold an absorbent article taking care not to stretch the waistfeatures. Assemble a vertical ring stand which supports a horizontalbar. Attach a spring loaded clamp to the left edge of the chassis,centered on the waist feature. Attach the clamp to the horizontalsupport so that the waist feature hangs vertically. Attach a secondclamp, which has a mass of 300 g±1 g, to the right edge of the chassis,centered on the midline of the waist feature. Allow the article to hangfor 30 seconds and then using the calibrated ruler measure the extendedlength of the waist feature to the nearest 1 mm. This is the ChassisExtended Length (CEL). The CEL can be used for all extended waistmeasures.

Unfold another absorbent article taking care not to stretch the waistfeatures. Place it on a horizontal bench surface with the back sheetfacing the bench and the top sheet facing upward. If present, unfold andlie flat any tabs or ears attached to the back half of the article.Identify the back waist feature of the article. Using a calibrated rulermeasure the lateral width of the waist feature along its longitudinalmidline. This is the Relaxed Length of the waist feature (RWL) Mark thewaist feature along its midline at 50% of its lateral width. This iswaist site 1 (WS1). Measure and mark two more sites, the first 1.5 cm tothe left of the 50% mark (WS2) and the second 1.5 cm to the right of the50% mark (WS3). Identify the proximal edge of the waist feature, i.e.the edge closest to the crotch of the article. Mark a lateral line 1.5cm from the proximal edge toward the crotch, and parallel to the waistfeature. Along a longitudinal axis that passes through WS1, mark theintersection at the lateral line just drawn (AS1). Repeat in likefashion for WS2 and WS3 to define sites AS2 and AS3 respectively.

Place the article, top sheet facing upward, onto the stainless steelplate. Secure the left distal edge of the chassis at the waist feature'smidline to the steel plate with adhesive tape. Grasp the right side ofthe chassis and pull until the waist feature has been extended equal tothe Chassis Extended Length (CEL). Secure the right side of the chassisto the steel plate with adhesive tape.

Place the steel plate with attached article on the anvil of the caliper.Place the caliper foot on a region of the steel plate that is notcovered by the article and zero the digital control. Using the caliper,measure the thickness at the six marked sites. Report to the nearest0.01 mm as Extended Waist Caliper EWC1, EWC2, and EWC3. Using acryogenic freeze spray gently remove the elastic feature from thearticle. Place the steel plate with attached article on the anvil of thecaliper and measure the thickness of the article at the sitescorresponding to WS1, WS2 and WS3. Report to the nearest 0.01 mm asExtended Back Sheet Caliper EBC1, EBC2, EBC3 respectively.

Calculate the Waist Feature Calipers as:Extended Waist Feature Caliper=[(EWC1−EBC1)+(EWC2−EBC2)+(EWC3−EBC3)]/3

Repeat this procedure for three identical articles and report as theaverage to the nearest 0.01 mm.

Waist Feature Percent Consolidation

Linear measurements are made using a calibrated ruler capable ofmeasuring to ±1 mm (traceable to National standards such as NIST). Alltesting is performed in a room maintained at about 23±2° C. and about50±2% relative humidity. All samples are conditioned for 2 hours beforetesting at about 23±2° C. and about 50±2% relative humidity.

Unfold the absorbent article taking care not to stretch the waistfeatures. Place it on a horizontal bench surface with the back sheetfacing the bench and the top sheet facing upward. If present, unfold andlie flat any tabs or ears attached to the back half of the article.Identify the back waist feature of the article. Using a calibrated rulermeasure the lateral width of the waist feature along its midline andrecord to the nearest 1 mm. This is the Relaxed Length of the waistfeature (RWL).

Using a cryogenic freeze spray (available as CytoFreeze, ControlCompany, TX) carefully remove the waist feature from the article. Placethe waist feature into a beaker with 100 mL of dichloromethane and soakfor 15 minutes to dissolve the adhesives. Remove the waist feature fromthe solvent and remove the elastics. Lay the waist feature substrateflat in a fume hood to dry. Assemble a vertical ring stand whichsupports a horizontal bar. Attach a spring loaded clamp, which is atleast as wide as the waist feature, to the left edge of the waistfeature. Attach the clamp to the horizontal support so that the waistfeature hangs vertically. Attach a second clamp, which has a mass of 3g±1 g and is at least as wide as the waist feature, to the right edge ofthe waist feature. Allow the article to hang for 30 seconds and thenusing the calibrated ruler measure the extended length of the waistfeature to the nearest 1 mm. This is the Extended Waist Feature Length(EWL).

Calculate the Full Waistband Consolidation as:% Full Waistband Consolidation=(EWL−RWL)/RWL×100

Repeat this procedure for three identical articles and report as theaverage to the nearest 1 mm.

Calculate the Extended Waistband Consolidation as:% Extended WaistbandConsolidation=(EWL−RWL)/RWL×100−(1−((CEL−RWL)/CEL)*100)

Repeat this procedure for three identical articles and report as theaverage to the nearest 1 mm.

Frequency of Waistband and Outer Leg Cuff Gathers on Taped DiaperProducts

The frequency of gathers for the waistband and outer leg cuffs isperformed using a template (FIG. 10) with manual counting of thegathers. The template is 25 mm wide by 80 mm long by 6 mm thick with a 5mm wide by 30 mm long window centered in the template. A lip 6 mm wideby 80 mm long by 6 mm thick is attached flush to the back edge of thetemplate. Taking care not to stretch the waistband, place the article ona horizontal bench with the backsheet facing downward. Referring to FIG.3, visually identify the CD and MD center of the waistband 2000 on thearticle. Place the template on top of, and parallel to, the waistbandwith the midpoint centered in the window. Manually count and record thenumber of gathers visible in the window. Again, taking care not tostretch the waistband, turn the article over such that the topsheet isnow facing downward. Visually identify the CD and MD center of thewaistband. Place the template on top of, and parallel to, the waistbandwith the midpoint centered in the window. Manually count and record thenumber of gathers visible in the window. In like fashion repeat thesetwo measures for the waistband 1000. Average the four values and reportto the nearest 0.1 gather per 30 mm.

Taking care not to stretch the Leg Gasketing System, place the articleon a horizontal bench with the backsheet facing downward. Referring toFIG. 3, visually identify the CD and MD center of the Leg GasketingSystem gather 70 on the article. Place the template on top of, andparallel to, the left Leg Gasketing with the midpoint centered in thewindow. Manually count and record the number of gathers visible in thewindow. In like fashion repeat for the right Leg Gasket. Average the twovalues and report to the nearest 0.1 gather. Average the two values andreport to the nearest 0.1 gather per 30 mm.

Calculate the Ratio of Leg Gasketing System Gather Count to WaistbandGather Count as follows:Ratio=Average Leg Gasketing System Gather Count/Average Waistband GatherCount

Repeat this procedure for three identical articles and report as theaverage to the nearest 0.01 units

CD Length Ratio

CD Length Ratio is the ratio of chassis extended length (CEL) toExtended Back Chassis Width (EBCW), as defined here.

Calculate the CD Length Ratio as follows:CD Length Ratio=CEL/EBCW

Repeat this procedure for three identical articles and report as theaverage.

First Waist Region Stiffness and First Waist Region Resiliency Method

First waist region stiffness and first waist region resiliency aremeasured using a constant rate of extension tensile tester with computerinterface (a suitable instrument is a MTS Insight Model 1 EL under TestWorks 4 software, as available from MTS Systems Corp., Eden Prairie,Minn.) fitted with a 25 N load cell. A plunger 300 shown in FIG. 20 andalso FIG. 21 (rotated 90 degrees) is used for the upper movable testfixture and a support platform 310 is used as the lower stationary testfixture. All testing is performed in a conditioned room maintained at23° C.±2 C.° and 50%±2% relative humidity.

The foot component 301 of the plunger 300 is made of two smoothPlexiglas sheets 302 and 303, 12 mm thick to maximize the available loadcell capacity. The shaft 304 is machined to fit the tensile tester andhas a locking collar 305 to stabilize the plunger and maintain alignmentorthogonal to the test surface 311 of the base support platform 310. Thefoot 301, is 300 mm deep by 50 mm high by 50 mm wide, and creates aright angle 306 with minimal radius on the material contacting surface307. The foot 301 is secured to the shaft 304 such that the bottom edge308 of the foot is parallel to the surface of the test surface 311.

The bottom fixture 310 is attached to the tensile tester with the shaft314 machined to fit the tensile tester and locking collar 315. Thelaterally movable support platform 312 is mounted on a rail 313 and hasa set screw 316 to lock its position after adjustment. The test surface311 is made from polished aluminum 500 mm wide by 300 mm deep and isattached to the top of the platform 312. The platform 312 extends 100 mmabove the top surface of rail 313.

Samples are conditioned at 23° C.±2 C.° and 50%±2% relative humidity for2 hours prior to testing. Four (4) patches of double sided adhesive tape(e.g. 3M Brand tape available from 3M, St. Paul, Minn.) are adhered tothe garment facing surface of the article to attach the specimen to thetesting platform 311. Place the article, back sheet facing upward, ontoa lab bench. At the waist to be tested, extend the article in thelateral direction until the article is laid flat. Secure the extendedarticle to the bench. Starting at the waist edge 321, measure down thelateral edge 350 the specified distance (e.g., 15 mm inboard of thewaist edge, or 10 mm inboard of the waist edge, etc.) and mark. Repeatfor the opposing lateral edge. Draw a line 322 across the back of thearticle connecting these two points. At the left edge 350 place a patchof adhesive tape 15 mm wide by 30 mm long with its long edge flush withthe article edge 350 and its width edge extending inboard from the line322. Repeat in like fashion for the right lateral edge of the article.From the longitudinal centerline 100 of the article, measure 26 mmlaterally toward the left distal edge of the article and mark (distance325). Place another 15 mm×30 mm patch of adhesive tape with its lengthedge parallel to the longitudinal axis of the product and its width edgeextending inboard from the line 322. Repeat in like fashion for theright side of the article. Set the gage height (distance 317 a) suchthat bottom surface 308 of the plunger foot 301 is 5.00±0.01 mm abovethe top plane of the test surface 311. Set the position of the platform312 such that nearest surface of foot 301 is offset 5.00 mm±0.01 mm awayfrom the side edge of the testing surface 318 (distance 317). Programthe tensile tester to complete the following steps 5 times: execute anextension cycle by lowering the crosshead downward 15.00 mm at a rate of51 mm/min while collecting displacement and force data at a rate 100 Hz;wait 2 seconds after completing the extension cycle; execute arelaxation cycle by raising the crosshead upward 15.00 mm at a rate of51 mm/min while collecting displacement and force data at a rate of 100Hz; wait 30 seconds after completing the relaxation cycle.

Referring to FIGS. 20 and 22, the article is adhered to the test surface311 garment-facing surface downward using the 2-sided tape just applied.With the article still fully extended, align the longitudinal centerlineof the article with the center of the foot 301, and line 322 alignedwith the edge of the test surface 311. Keeping this alignment, lower andadhere the article onto the test surface 311. If the front waist edge321 can be adjusted to present either a convex or concave surface to thebottom face 308 of plunger 301 after being attached, arrange the waistedge 321 to present a concave surface relative to the test edge 318 ofthe test surface 311. Arrange the rest of the specimen 320 on the testsurface 311 such that any longitudinal contraction in the article (e.g.,contraction from leg cuff elastics) causes folds 323,324 to form awayfrom the test surface 311. Ensure all materials in the article are lyingin a flat out state up to fold 324 such that no material is flippedover, bent, or twisted. Ensure all portions of the specimen 320, otherthan the portions between the marked location 322 and the waist edge321, will not interfere with the motion of the plunger. A weighted block330 may be used to hold the back of the article out of the way of theplunger.

Zero the load cell and the crosshead position. Start the test andcollect data. An exemplary chart created by Excel utilizing the raw datagenerated by the Test Works 4 software is shown in FIG. 23. From theresulting force (N) verses displacement curves (mm) calculate the PeakForce (N) during the second extension cycle and report to the nearest0.1N. Also, calculate the Area (mJ) under the fifth relaxation cycle andreport to the nearest 0.1 mJ. Repeat the test for a total of 15substantially identical articles. Report the Waist Region Stiffness asan average of the Peak Force (from 2^(nd) cycle) of the 15 replicates tothe nearest 0.1 N. Report the Waist Region Resiliency as an average ofthe Area of the 15 replicates to the nearest 0.1 mJ.

Regularity and Uniformity Methods for Waist Assembly Corrugations

Corrugation Regularity

Draw a line across the product at the edge of the second section in thefirst waist region. The line should be parallel to the waist edge, and15 mm inboard of the waist edge. Follow the drawn line from onelongitudinal edge of the product to the opposite longitudinal edge ofthe product. For each corrugation apex encountered traversing the drawnline (i.e., a location where the product is deformed in the z-direction,and said deformation reaches a vertical apex with respect to theadjacent vertical deformations along the drawn line), measure thedistance in millimeters from the current corrugation apex to the nextcorrugation apex along the drawn line. Record each of these individualdistances in millimeters. Average all individual distances. For eachindividual distance, calculate the absolute value of the differencebetween the individual distance and the average of all individualdistances. Calculate the percentage of differences which are less than 1mm. Record this percentage as the Corrugation Regularity.

Corrugation Uniformity

Draw a line across the product at the inboard edge of the waist assemblyin the first waist region. If there is no waistband or the waistband ofthe product is more than 25 mm long, the line should be parallel to thewaist edge, and 25 mm inboard of the waist edge. If the waistband isless than 25 mm long, the line should be drawn at the inboard edge ofthe waistband. Follow the waist edge 14 of the first waist region 36from one longitudinal edge of the product to the opposite longitudinaledge of the product. Count each corrugation apex (i.e., a location wherethe product is deformed in the z-direction, and said deformation reachesa vertical apex with respect to the adjacent vertical deformations)along the waist edge, and record the total number of corrugation apexes.For each corrugation apex encountered along the waist edge 14, followthe path of the ridge stemming from the corrugation apex longitudinallyinboard. A ridge is defined as a longitudinally running continuousseries of local high points in the z-direction which meet the definitionof a vertical apex at any point along its length by drawing anintersecting line parallel to the waist edge. If the ridge is broken(i.e., reaches a location where the ridge can no longer be followedbecause it no longer fits its definition of a single ridge) prior toreaching the drawn line, record this as a broken corrugation. If theridge splits in to two or more paths where each path meets thedefinition of a ridge prior to reaching the drawn line, record this as abroken corrugation. If the ridge joins with a ridge of a previouslycounted corrugation apex prior to reaching the drawn line, record thisas a broken corrugation. If the ridge reaches the drawn line without anyof the aforementioned results, record this as a complete corrugation.Calculate the percentage of complete corrugations in relation to thetotal number of corrugation apexes. Record this percentage as theCorrugation Uniformity.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numeral values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm”.

All documents cited in the Detailed Description of the Invention are, inrelevant part, incorporated herein by reference; the citation of anydocument is not to be construed as an admission that it is prior artwith respect to the disposable absorbent articles detailed herein. Tothe extent that any meaning or definition of a term in this writtendocument conflicts with any meaning or definition of the term in adocument incorporated by reference, the meaning or definition assignedto the term in this written document shall govern.

While particular embodiments of the disposable absorbent articlesdetailed herein have been illustrated and described, it would be obviousto those skilled in the art that various other changes and modificationscan be made without departing from the spirit and scope of theinvention. It is therefore intended to cover in the appended claims allsuch changes and modifications that are within the scope of thisinvention.

What is claimed is:
 1. An open form disposable absorbent articlecomprising: a first waist region, a second waist region, a crotch regiondisposed between the first waist region and second waist region, a waistedge in the first waist region, at least one waistband in the firstwaist region, at least one fastener in the second waist region, a leggasketing system, and at least one discrete landing zone in the firstwaist region, the discrete landing zone comprising a lateral inboardedge, wherein the discrete landing zone and the waistband overlap toform an overlap region in the first waist region, and wherein thewaistband does not overlap the lateral inboard edge of the discretelanding zone; wherein the waistband comprises a nonwoven material,wherein the nonwoven material comprises a bond pattern formed therein,the bond pattern comprising a plurality of bonded areas and a pluralityof unbonded areas positioned between corresponding adjacent bondedareas, and wherein the plurality of bonded areas define a plurality ofbond lines where the fibers of the nonwoven material are joined togetherby thermal bonds, pressure bonds, and/or ultrasonic welds; wherein thebond pattern is configured to form corrugations in the nonwoven materialof the waistband, wherein the plurality of bonded areas extend in agenerally longitudinal direction of the absorbent article, and whereinthe corrugations in the nonwoven material of the waistband extendgenerally parallel to the plurality of bonded areas in the longitudinaldirection; wherein the waistband further comprises an elastomeric filmand/or elastic strands; wherein when the nonwoven material of thewaistband is in an uncontracted state, at least a portion of theunbonded areas extend in a z-direction above the adjacent bonded areas;and wherein at least a portion of the waistband does not form abody-facing surface of the absorbent article.
 2. The open formdisposable absorbent article of claim 1, wherein the first waist regionhas a resiliency of greater than 5 mJ.
 3. The open form disposableabsorbent article of claim 1, wherein the first waist region has astiffness of less than 10 N.
 4. The open form disposable absorbentarticle of claim 1, wherein the basis weight of the nonwoven material isabout 30 gsm.
 5. The open form disposable absorbent article of claim 1,wherein the open form disposable absorbent article comprises an earcomprising a zero strain stretch laminate.
 6. The open form disposableabsorbent article of claim 1, wherein the first waist region has astiffness of less than 8.5 N.
 7. The open form disposable absorbentarticle of claim 1, wherein the waistband comprises a first end regionand a second end region, wherein the waistband is attached on thebody-facing surface of the open form disposable absorbent article, andwherein the leg gasketing system at least partially overlaps thewaistband in the first end region and second end region to form aportion of the body-facing surface.
 8. The open form disposableabsorbent article of claim 1, wherein the waistband is coterminous withthe waist edge of the first waist region.
 9. The open form disposableabsorbent article of claim 1, wherein the waistband laterally terminateswithin the span of the leg gasketing system.
 10. The open formdisposable article of claim 1, wherein the leg gasketing system does notinclude a polymeric film.
 11. The open form disposable article of claim1, wherein the leg gasketing system comprises an N-fiber material. 12.The open form disposable absorbent article of claim 1, wherein thewaistband comprises at least three elastic strands.
 13. The open formdisposable absorbent article of claim 1, wherein at least one of theelastic strands is round in cross section.
 14. An open form disposableabsorbent article comprising: a chassis comprising a first waist region,a second waist region, a crotch region disposed between the first waistregion and second waist region, a waist edge in the first waist region,at least one waistband laminate discretely applied to the chassis in thefirst waist region, at least one fastener in the second waist region, atopsheet, a backsheet, a leg gasketing system, and an absorbent coredisposed between the topsheet and backsheet, the absorbent core having alateral edge disposed in the first waist region, the lateral edge of thecore being inboard of the waist edge in the first waist region; whereinthe absorbent core and the waistband laminate overlap to form an overlapregion in the first waist region; wherein the waistband laminatecomprises a nonwoven material and an elastomeric film and/or elasticstrands, wherein the nonwoven material comprises a wavy bond patternformed therein, the wavy bond pattern comprising a plurality of bondedareas where the fibers of the nonwoven material are joined together bythermal bonds, pressure bonds, and/or ultrasonic welds, wherein the wavybond pattern is configured to form corrugations in the nonwoven materialof the waistband laminate, wherein the plurality of bonded areas extendin a generally longitudinal direction of the absorbent article, andwherein the corrugations in the nonwoven material of the waistbandlaminate extend generally adjacent to the plurality of bonded areas inthe longitudinal direction; wherein at least a portion of the waistbandlaminate does not form a body-facing surface of the absorbent article;and wherein the nonwoven material and the elastomeric film and/orelastic strands are combined under a first strain and the waistbandlaminate is attached to the open form disposable absorbent article underan applied waistband strain, wherein the difference between the firststrain and the applied waistband strain results in a waistband having aFull Waistband Consolidation of greater than 95%.
 15. The open formdisposable absorbent article of claim 14, wherein the first waist regionhas a resiliency of greater than 5 mJ.
 16. The open form disposableabsorbent article of claim 14, wherein the first waist region has astiffness of less than 10 N.
 17. The open form disposable absorbentarticle of claim 14, wherein the waistband laminate comprises a firstend region and a second end region, wherein the waistband laminate isattached on the body-facing surface of the open form disposableabsorbent article, and wherein the leg gasketing system at leastpartially overlaps the waistband laminate in the first end region andsecond end region to form a portion of the body-facing surface.
 18. Theopen form disposable absorbent article of claim 1, wherein the waistbandcomprises crimped or curled fibers.
 19. The open form disposableabsorbent article of claim 1, wherein the waistband is bonded to thefirst waist region by glue, thermal bonds, and/or compression welds. 20.The open form disposable absorbent article of claim 1, wherein the bondpattern repeats in a lateral direction.
 21. The open form disposableabsorbent article of claim 1, wherein the second waist region comprisesa second waistband.
 22. The open form disposable absorbent article ofclaim 1, wherein the waistband does not comprise foam.
 23. The open formdisposable absorbent article of claim 1, wherein the open formdisposable absorbent article comprises an opacity strengthening patch.24. The open form disposable absorbent article of claim 1, wherein thenonwoven material and the elastomeric film and/or elastic strands arecombined under a first strain and the waistband is attached to the openform disposable absorbent article under an applied waistband strain,wherein the difference between the first strain and the appliedwaistband strain results in a waistband having a Full WaistbandConsolidation of greater than 95%.
 25. The open form disposableabsorbent article of claim 1, wherein when the nonwoven material iselastically contracted, the bonded areas will buckle and the unbondedareas will pucker up, thereby creating the corrugations extending in thelongitudinal direction.
 26. The open form disposable absorbent articleof claim 14, wherein a plurality of unbonded areas are positionedbetween corresponding adjacent bonded areas and wherein when thenonwoven material is elastically contracted, the bonded areas willbuckle and the unbonded areas will pucker up, thereby creating thecorrugations extending in the longitudinal direction.
 27. The open formdisposable absorbent article of claim 1, further comprising a chassiscomprising a topsheet and a backsheet, wherein the nonwoven material andthe elastomeric film and/or elastic strands define a waistband laminate,and wherein the waistband laminate is discretely applied to the chassisin the first waist region.
 28. The open form disposable absorbentarticle of claim 14, wherein the plurality of bonded areas define aplurality of substantially continuous bond lines, wherein a plurality ofunbonded areas are positioned between corresponding adjacent bondedareas, and wherein when the nonwoven material of the waistband laminateis in an uncontracted state, at least a portion of the unbonded areasextend in a z-direction above the adjacent bonded areas.